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Yamaha VINO YJ50RAR Owner's Manual

Other manuals for VINO YJ50RAR: Service Manual

Summary of VINO YJ50RAR

  • Page 1

    Printed in japan 2002·5–3.4 ×1(e) ! Printed on recycled paper yamaha motor co., ltd. Owner’s manual 5ly-28199-13 lit-11626-16-23 yj50rar yj50rr.

  • Page 2

    Eau03438.

  • Page 3: Introduction

    Eau00000 introduction congratulations on your purchase of the yamaha yj50r. This model is the result of yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made yamaha a leader...

  • Page 4: Important Manual Information

    Eau00003 important manual 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! Failure to follow warning instructions could result in severe injury or death to the sc...

  • Page 5: Important Manual Information

    Important manual information ew000000 w please read this manual and the “you and your motorcycle: riding tips” booklet carefully and completely before operating this scooter. Do not attempt to operate this scooter until you have attained adequate knowl- edge of its controls and operating features an...

  • Page 6

    Yj50rr/yj50rar owner’s manual ©2002 by yamaha motor corporation, u.S.A. 1st edition, april 2002 all rights reserved. Any reprinting or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Printed in japan. P/n lit-11626-16-23 eau04247 affix dea...

  • Page 7: Table of Contents

    Eau00009 table of contents safety information ...................................1-1 safe riding .......................................................1-1 protective apparel ...........................................1-2 modifications ...................................................1-3 loading a...

  • Page 8: Table of Contents

    Adjusting the throttle cable free play .............6-10 tires ..............................................................6-10 adjusting the front and rear brake lever free play .....................................................6-12 checking the front and rear brake shoes ......6-13 checking a...

  • Page 9: Q Safety Information

    1-1 eau00011 q safety information 1 scooters are single track vehicles. Their safe use and operation are depen- dent upon the use of proper riding techniques as well as the expertise of the operator. Every operator should know the following requirements before riding this scooter. He or she should: ...

  • Page 10: Q Safety Information

    1-2 q safety information 1 4. Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current driver’s license. A. Make sure that you are qualified and that you only lend your scooter to other qualified opera- tors. B. Know your ...

  • Page 11: Q Safety Information

    1-3 q safety information 1 3. The use of a jacket, substantial shoes, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations. 4. Never wear loose-fitting clothes, otherwise they could catch on the control levers or wheels and cause injury or an accident. 5. Never tou...

  • Page 12: Q Safety Information

    1-4 q safety information 1 2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely attached to the scooter before riding. Check accessory mounts and cargo restraints fre- quently. 3. Never attach any large or heavy items to the handlebar, front fork, or f...

  • Page 13: Q Safety Information

    1-5 q safety information 1 c. Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability, therefore, such accessories are not recommended. 2. Use caution when adding electri...

  • Page 14: Q Safety Information

    1-6 q safety information 1 eau00023 further safe-riding points 1. Make sure to signal clearly when making turns. 2. Braking can be extremely difficult on a wet road. Avoid hard braking, because the scooter could slide. Apply the brakes slowly when stopping on a wet surface. 3. Slow down as you appro...

  • Page 15: Q Safety Information

    1-7 q safety information 1 eau02977 location of important labels please read the following important labels carefully before operating this scooter. 1 2 3 4 5 5ly-9-13 (us) 4/23/02 4:16 pm page 13.

  • Page 16: Q Safety Information

    1-8 q safety information 1 1 2 5 q warning before you operate this vehicle, read the owner’s manual and all labels. Always wear an approved motorcycle helmet, eye protection, and protective clothing. Never carry a passenger. You increase your risk of losing control if you carry a passenger. 3sl-2118...

  • Page 17: Q Safety Information

    1-9 q safety information 1 5ly-9-13 (us) 4/23/02 4:16 pm page 15.

  • Page 18: Description

    2-1 eau00026 description 2 1. Front wheel 2. Front fender 3. Front turn signal light 4. Rear turn signal light 5. Rear wheel 6. Kickstarter (page 3-9) 7. Air filter element (page 6-8) 8. Battery (page 6-14) 1 2 3 4 5 6 7 8 left view 5ly-9-13 (us) 4/23/02 4:16 pm page 16.

  • Page 19: Description

    2-2 description 2 9. Tail/brake light 10. Carrier (page 3-11) 11. 2-stroke engine oil tank cap cover (page 3-8) 12. Seat (page 3-9) 13. Headlight 14. Spark plug (page 6-5) 15. Centerstand 16. Muffler 13 12 10 9 16 15 11 14 right view 5ly-9-13 (us) 4/23/02 4:16 pm page 17.

  • Page 20: Description

    2-3 description 2 1. Rear brake lever (page 3-5) 2. Left handlebar switches (page 3-4) 3. Fuel gauge (page 3-4) 4. Speedometer unit (page 3-3) 5. Main switch/steering lock (page 3-1) 6. Right handlebar switches (page 3-4) 7. Front brake lever (page 3-5) 8. Throttle grip (page 5-3, 6-10) 1 2 3 4 5 6 ...

  • Page 21

    3-1 eau00027 instrument and control functions 3 eau00029 main switch/steering lock the main switch/steering lock con- trols the ignition and lighting systems, and is used to lock the steering. The various positions are described below. Eau04384 on all electrical circuits are supplied with power, the...

  • Page 22

    3-2 to lock the steering 1. Turn the handlebars all the way to the left. 2. Push the key in from the “off” position, and then turn it to “lock” while still pushing it. 3. Remove the key. To unlock the steering push the key in, and then turn it to “off” while still pushing it. Instrument and control ...

  • Page 23

    3-3 instrument and control functions 3 note: if the 2-stroke engine oil level warn- ing light does not come on when the key is in the “ * ” position or does not go off after the 2-stroke engine oil tank has been refilled, have a yamaha dealer check the electrical circuit. Eca00125 c c do not operate...

  • Page 24

    3-4 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 nee- dle reaches “e”, refuel as soon as possible. Note: do not allow the fuel tank to empty itself completely. Instrument and control funct...

  • Page 25

    3-5 instrument and control functions 3 eau00143 start switch “ ,” push this switch to crank the engine with the starter. Ec000005 c c see page 5-1 for starting instruc- tions prior to starting the engine. Eau00163 rear brake lever the rear brake lever is located on the left handlebar grip. To apply ...

  • Page 26

    3-6 eau03447 fuel tank cap to remove the fuel tank cap slide the lock cover open, insert the key into the lock, and then turn it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be removed. Instrument and control functions 3 a 1 1. Fuel tank cap lock cover a. Unlock. Ew000024 ...

  • Page 27

    3-7 instrument and control functions 3 eau03753 fuel make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. Ew000130 w 8 do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands. 8 avoid spilling fuel on t...

  • Page 28

    3-8 your yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(r+m)/2] of 86 or higher, or a research octane 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 ...

  • Page 29

    3-9 instrument and control functions 3 eau02978 seat to open the seat 1. Insert the key in the lock, and 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 secure...

  • Page 30

    3-10 eau00262 helmet holder the helmet holder is located under the seat. To secure a helmet to the helmet holder 1. Open the seat. (see page 3-9 for opening procedures.) 2. Attach the helmet to the helmet holder, and then securely close the seat. Instrument and control functions 3 1 1. Helmet holder...

  • Page 31

    3-11 instrument and control functions 3 ec000010 c c keep the following points in mind when using the storage compart- ment. 8 since the storage compart- ment accumulates heat when exposed to the sun, do not store anything susceptible to heat inside it. 8 to avoid humidity from spreading through the...

  • Page 32: Pre-Operation Checks

    4-1 eau01114 pre-operation checks 4 the condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect- edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak- age or loss of tire a...

  • Page 33: Pre-Operation Checks

    4-2 pre-operation checks 4 note: pre-operation checks should be made each time the scooter 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. Ewa00033 w if any item in the pre-operation check list is not working...

  • Page 34

    5-1 eau00372 operation and important riding points 5 eau01118 w 8 become thoroughly familiar with all operating controls and their functions before riding. Consult a yamaha dealer regarding any control or func- tion that you do not thorough- ly understand. 8 never start the engine or oper- ate it in...

  • Page 35

    5-2 operation and important riding points 5 eca00126 c c if the 2-stroke engine oil level warning light does not come on, have a yamaha dealer check the electrical circuit. 3. Close the throttle completely. 4. Start the engine by pushing the start switch or by pushing the kickstarter lever down, whi...

  • Page 36

    5-3 operation and important riding points 5 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. Eau00435 braking 1. Close the throttle completely. 2. Apply both front and rear brakes simultaneously while gradually ...

  • Page 37

    5-4 operation and important riding points 5 8 railroad crossings, streetcar rails, iron plates on road con- struction sites, and manhole covers become extremely slip- pery when wet. Therefore, slow down when approaching such areas and cross them with caution. 8 keep in mind that braking on a wet roa...

  • Page 38

    5-5 operation and important riding points 5 1,000 km (600 mi) and beyond avoid prolonged full-throttle opera- tion. Vary the engine speed occa- sionally. Ec000049 c c if any engine trouble should occur during the engine break-in period, immediately have a yamaha dealer check the vehicle. Ew000058 w ...

  • Page 39

    6-1 eau00462 periodic maintenance and minor repair 6 eau03453 safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condi- tion possible. The most important points of scooter inspection, adjust- ment, and lubrica...

  • Page 40

    6-2 periodic maintenance and minor repair 6 eau00473 periodic maintenance and lubrication chart no. Item routine initial 300 mi (500 km) every 2,000 mi (3,000 km) or 6 months 4,000 mi (6,000 km) or 12 months 1 spark plug • check condition. • clean or replace if necessary. √ √ √ 2 air filter element ...

  • Page 41

    6-3 periodic maintenance and minor repair 6 *since these items require special tools, data and technical skills, have a yamaha dealer perform the service. **lithium-soap-based grease eau04316 note: from 6,000 mi (9,000 km) or 18 months, repeat the maintenance intervals starting from 2,000 mi (3,000 ...

  • Page 42

    6-4 periodic maintenance and minor repair 6 eau01777 removing and installing the panel the panel shown above needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed. 1 1. Panel a 2. Remove the ...

  • Page 43

    6-5 periodic maintenance and minor repair 6 eau03972 checking the spark plug the spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic mainte...

  • Page 44

    6-6 periodic maintenance and minor repair 6 to check the spark plug 1. Check that the porcelain insula- tor around the center electrode of the spark plug is a medium-to- light tan (the ideal color when the scooter is ridden normally). Note: if the spark plug shows a distinctly different color, the e...

  • Page 45

    6-7 periodic maintenance and minor repair 6 eau04228 final transmission oil the final transmission case must be checked for oil leakage before each ride. If any leakage is found, have a yamaha dealer check and repair the scooter. In addition, the final trans- mission oil must be changed as fol- lows...

  • Page 46

    6-8 periodic maintenance and minor repair 6 eau04349 cleaning the air filter sponge material the air filter sponge material should be cleaned at the intervals specified in the periodic maintenance and lubri- cation chart. Clean the air filter sponge material more frequently if you are riding in unus...

  • Page 47

    6-9 periodic maintenance and minor repair 6 eca00111 c c to avoid damaging the air filter sponge material, handle it gently and carefully, and do not twist it. 4. Apply oil of the recommended type to the entire surface of the air filter sponge material, and then squeeze the excess oil out. Note: the...

  • Page 48

    6-10 periodic maintenance and minor repair 6 eau00635 adjusting the throttle cable free play the throttle cable free play should measure 1.5–3.5 mm (0.06–0.14 in) at the throttle grip. Periodically check the throttle cable free play and, if necessary, have a yamaha dealer adjust it. A a. Throttle ca...

  • Page 49

    6-11 periodic maintenance and minor repair 6 8 never overload the scooter! Operation of an overloaded scooter may result in tire damage, loss of control, or severe injury. Make sure that the total weight of rider, cargo, and accessories does not exceed the specified maxi- mum load for the vehicle. 8...

  • Page 50

    6-12 periodic maintenance and minor repair 6 tire information this scooter is equipped with panel wheels and tubeless tires. Eau00702 adjusting the front and rear brake lever free play the front and rear brake lever free play should measure 10–20 mm (0.4–0.8 in) as shown. Periodically check the fron...

  • Page 51

    6-13 periodic maintenance and minor repair 6 to increase the brake lever free play, turn the adjusting nut at the brake shoe plate in direction a. To decrease the brake lever free play, turn the adjusting nut in direction b. Ew000101 w if proper adjustment cannot be obtained as described, have a yam...

  • Page 52

    6-14 periodic maintenance and minor repair 6 eau00774 adjusting the autolube pump the autolube pump is a vital and sophisticated component of the engine, which must be adjusted by a yamaha dealer at the intervals speci- fied in the periodic maintenance and lubrication chart. Eau03989 battery this sc...

  • Page 53

    6-15 periodic maintenance and minor repair 6 8 batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space. 8 keep this and all batter- ies out of the reach of children. To ...

  • Page 54

    6-16 periodic maintenance and minor repair 6 to charge the battery have a yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to dis- charge more quickly if the scooter is equipped with optional electrical accessories. To store the...

  • Page 55

    6-17 periodic maintenance and minor repair 6 ec000103 c c do not use a fuse of a higher amperage rating than recommend- ed to avoid causing extensive damage to the electrical system and possibly a fire. 3. Turn the key to “on” and turn on the electrical circuits to check if the devices operate. 4. I...

  • Page 56

    6-18 periodic maintenance and minor repair 6 eau01397 troubleshooting chart ew000125 w keep away open flames and do not smoke while checking or working on the fuel system. Check the fuel level in the fuel tank. 1. Fuel there is enough fuel. There is no fuel. Check the compression. Supply fuel. The e...

  • Page 57: Scooter Care and Storage

    7-1 eau03434 scooter care and storage 7 care while the open design of a scooter reveals the attractiveness of the tech- nology, it also makes it more vulnera- ble. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it det...

  • Page 58: Scooter Care and Storage

    7-2 scooter care and storage 7 8 do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abra- sive cleaning products, sol- vent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or el...

  • Page 59: Scooter Care and Storage

    7-3 scooter care and storage 7 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 induced discoloring of stainless- steel exhaust systems can be removed...

  • Page 60: Scooter Care and Storage

    7-4 scooter care and storage 7 storage short-term always store your scooter in a cool, dry place and, if necessary, protect it against dust with a porous cover. Eca00015 c c 8 storing the scooter in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humi...

  • Page 61: Scooter Care and Storage

    7-5 scooter care and storage 7 5. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand. 6. Check and, if necessary, correct the tire air pressure, and then lift the scooter so that both of its wheels are off the ground. Alternatively, ...

  • Page 62: Specifications

    8-1 eau01038 specifications 8 specifications model yj50r/yj50ra dimensions overall length 1,630 mm (64.2 in) overall width 630 mm (24.8 in) overall height 1,030 mm (40.6 in) seat height 715 mm (28.1 in) wheelbase 1,150 mm (45.3 in) ground clearance 85 mm (3.3 in) minimum turning radius 1,600 mm (63....

  • Page 63: Specifications

    8-2 specifications 8 transmission primary reduction system helical gear primary reduction ratio 3.692 secondary reduction system spur gear secondary reduction ratio 3.230 transmission type v-belt automatic operation centrifugal automatic type chassis frame type steel tube underbone caster angle 25° ...

  • Page 64: Specifications

    8-3 specifications 8 wheel travel front 52 mm (2.05 in) rear 48 mm (1.89 in) electrical system ignition system dc. C.D.I. Charging system type a.C. Magneto standard output 14 v, 120 w @ 5,000 r/min battery model gt4b-5 voltage, capacity 12 v, 2.5 ah headlight type halogen bulb bulb voltage, wattage ...

  • Page 65: Consumer Information

    9-1 eau01039 consumer information 9 eau02944 identification numbers record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a yamaha dealer or for reference in case the vehicle is stole...

  • Page 66: Consumer Information

    9-2 consumer information 9 eau04476 model label the model label is affixed to the inside of the storage compartment. (see page 3-10 for storage compart- ment opening and closing proce- dures.) record the information on this label in the space provided. This information will be needed when ordering s...

  • Page 67: Consumer Information

    9-3 consumer information 9 eau01051 reporting safety defects if you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should imme- diately inform the national highway traffic safety administration (nhtsa) in addition to notifying yamaha motor corpor...

  • Page 68: Consumer Information

    9-4 consumer information 9 eau01055 scooter noise regulation tampering with noise control system prohibited: federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any d...

  • Page 69: Consumer Information

    9-5 consumer information 9 5ly-9-13 (us) 4/23/02 4:16 pm page 67.

  • Page 70: Consumer Information

    9-6 consumer information 9 eau02919 yamaha motor corporation, u.S.A. Riva limited warranty 5ly-9-13 (us) 4/23/02 4:16 pm page 68.

  • Page 71: Consumer Information

    9-7 consumer information 9 5ly-9-13 (us) 4/23/02 4:16 pm page 69.

  • Page 72: Consumer Information

    9-8 consumer information 9 eau01063 yamaha extended service (y.E.S.) 5ly-9-13 (us) 4/23/02 4:16 pm page 70

  • Page 73: Consumer Information

    9-9 consumer information 9 5ly-9-13 (us) 4/23/02 4:16 pm page 71.

  • Page 74

    Printed in japan 2002·5–3.4 ×1(e) ! Printed on recycled paper yamaha motor co., ltd. Owner’s manual 5ly-28199-13 lit-11626-16-23 yj50rar yj50rr.