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Yamaha ZUMA CW50N Owner's Manual

Other manuals for ZUMA CW50N: Service Manual

Summary of ZUMA CW50N

  • Page 1

    5lu-f8199-11 cw50n owner’s manual lit-11626-14-16.

  • Page 2: Warning

    The engine exhaust from this product contains chemicals know to the state of california to cause cancer, birth defects or other reproductive harm. Warning yamaha lit-calif-65-01.

  • Page 3: Introduction

    Introduction eaa20301 congratulations on your purchase of the yamaha cw50. 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 Informations

    Important informations eaa10500 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 scooter ...

  • Page 5: Important Informations

    Important informations euu00001 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 ...

  • Page 6

    Eaa00100 cw50n owner’s manual © 2000 by mbk industrie 2nd edition, april 2000 all rights reserved. Any reproduction or representation without the written permission of mbk industrie is expressly prohibited. Printed in france p/n lit-11626-14-16 affix dealer label here.

  • Page 7: Table of Contents

    1 2 3 4 5 6 7 8 9 1 give safety the right of way 3 description 4 instrument and control functions 5 pre-operation checks 6 operation and important riding points 7 periodic maintenance and minor repair 8 scooter care and storage 9 specifications 10 consumer information index 10 2 location of the impo...

  • Page 8

    1 think of your safety .............................................................. 1-1 safety information ................................................................. 1-2 safe riding ........................................................................................ 1-3 protective appar...

  • Page 9

    1 1-1 give safety the right of way euu75900 think of your safety both scooters and mopeds are fascinating vehicles which give a tremendous feeling of freedom to their riders. They must be correctly maintained at all times in order to ensure optimum performance. However, as a rider you must also ensu...

  • Page 10

    1 1-2 give safety the right of way euu77201 safety information two-wheeled 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 ...

  • Page 11

    1 1-3 give safety the right of way safe riding 1. Always make pre-operation checks. Careful checks may help prevent an accident. 2. This scooter is designed to carry the operator and passenger in certain conditions (check the relevant regulation of each country). 3. Most traffic accidents involving ...

  • Page 12

    1 1-4 give safety the right of way 8. Never carry any object which can cause danger if they fall off (pointed or sharp objects, for example). 9. This scooter is designed for on-road use only. It is not suitable for off-road use. 10. Always be particularly attentive when riding the scooter, and take ...

  • Page 13

    1 1-5 give safety the right of way loading and accessories adding accessories or cargo to your scooter can adversely affect stability and handling if the weight distribution of the scooter is changed. To avoid the possibility of an accident, extreme caution should be used if adding cargo or accessor...

  • Page 14

    1 1-6 give safety the right of way accessories yamaha original accessories have been specially designed for use on this scooter. Because yamaha can not test every accessory which is available on the market, the owner is personally responsible for the selection, fitting and use of accessories of othe...

  • Page 15

    1 1-7 give safety the right of way gasoline and exhaust gas 1. Gasoline is highly flammable: a. Always turn off the engine when refueling. B. Take care not to spill any gasoline on the engine or exhaust pipe(s)/muffler(s) when refueling. C. Never refuel while smoking or in the vicinity of an open fl...

  • Page 16

    1 1-8 give safety the right of way recommendations in case of accident if the scooter has been in an accident, it is imperative that the following points are checked: 1. The good condition of the entire braking system, including the levers, cables and lines, etc ... 2. The good condition of the acti...

  • Page 17

    2 location of the important labels location of the important labels ....................................................... 2-1.

  • Page 18

    2 2-1 eaa40000 location of the important labels please read following labels carefully before operating the scooter. Location of the important labels 1 3 / 4 2 5 6.

  • Page 19

    2 2-2 location of the important labels warning i m p r o p e r l o a d i n g c a n c a u s e l o s s o f c o n t r o l . R e a d o w n e r ' s m a n u a l f o r p r o p e r l o a d i n g . 3jj-28446-a0 warning • b e f o r e y o u o p e r a t e t h i s v e h i c l e , r e a d t h e o w n e r ' s m a ...

  • Page 20: Description

    3 description left view ........................................................................................... 3-1 right view......................................................................................... 3-2 controls /instruments .........................................................

  • Page 21: Description

    3 fau00026 description left view 1. Rear brake lever (page 4-6) 2. Left handlebar switches (page 4-4) 3. Fuel tank (page 4-6) 4. Seat lock (page 4-10) 5. Oil tank (page 4-6) 6. Rear carrier (page 4-10) 3-1 7. Rear light (page 7-18) 8. Rear brake wear indicator (page 7-11) 9. Kick starter (page 4-9) ...

  • Page 22: Description

    3 right view description 3-2 1. Main switch (page 4-1) 2. Throttle grip (page 7-7) 3. Right handlebar switches (page 4-5) 4. Front brake lever (page 4-5) 5. Headlight (page 7-18) 6. Rear footrest 7. Centerstand (page 7-14) 8. Rear flasher light (page 7-19) 9. Passenger handle 1 2 3 4 5 6 7 8 9.

  • Page 23: Description

    3 controls/instruments description 3-3 1. Speedometer (page 4-4) 2. “high beam” indicator light “ ” (page 4-1) 3. “turn” indicator light “ ” (page 4-1) 4. “oil” warning indicator light “ ”(page 4-2) 5. Fuel gauge (page 4-4) 6. “horn” switch “ ”(page 4-4) 7. “turn” signal switch “ ”(page 4-4) 8. Star...

  • Page 24

    4 instrument and control functions main switch ...................................................................................... 4-1 indicator lights .................................................................................. 4-1 oil warning light circuit check .............................

  • Page 25

    4 fau00027 instrument and control functions 4-1 push lock off on 1. “high beam” indicator light “ ” 2. “turn” indicator light “ ” 3. “oil” level indicator light “ ” eab10000 indicator lights eab12403 “turn” indicator light “ ” : this indicator flashes when the turn switch is moved to the left or rig...

  • Page 26

    4 4-2 instrument and control functions eab11503* oil level indicator light “ ” : the light comes on when the main switch is at “ * ” or when there is little oil in the oil tank during operation. If the oil warning light comes on during operation, refill the tank immediately with yamalube 2-cycle eng...

  • Page 27

    4 instrument and control functions 4-3 eab31200 oil warning light circuit check * turn the main switch to "off". Turn the main switch to " ". Disconnected circuit, short circuit, faulty light bulb, etc. Ask a yamaha dealer to inspect. Supply engine oil ask a yamaha dealer to inspect turn the main sw...

  • Page 28

    4 instrument and control functions 4-4 1. Speedometer 2. Odometer 3. Fuel gauge 1. “horn” switch “ ” 2. “turn” switch “ ” 3. “lights” (dimmer) switch “ , ” eab60000 handlebar switches 10 20 30 0 40 mph mile highb eam turn oil f e fu e l 0 10 20 30 40 50 60 1 1 2 3 eab50701 fuel gauge the fuel gauge ...

  • Page 29

    4 instrument and control functions 4-5 1. Start switch “ ” 2. “engine stop” switch 1. Front brake lever 1 2 eab61901 start switch “ ” the starter motor cranks the engine when pushing the starter switch while applying the front or rear brake. Euu30700 see starting instructions prior to starting the e...

  • Page 30

    4 instrument and control functions 4-6 1. Fuel tank cap 2. Oil tank cap 1. Rear brake lever close open 2 1 1. Filler tube 2. Fuel level 1 2 eab90201 rear brake lever the rear brake lever is located on the left handlebar. Pull it toward the handlebar to apply the rear brake. 1 warning eac00651 fuel a...

  • Page 31

    4 instrument and control functions 4-7 caution: euu39302 always wipe off spilled fuel immediately with a dry and clean soft cloth. Fuel may deteriorate painted surfaces or plastic parts. Eae81701 recommended fuel: unleaded fuel fuel tank capacity: total: 4.6 l (1.01 imp gal, 1.21 us gal) your yamaha...

  • Page 32

    4 instrument and control functions 4-8 1. Starter lever (choke) caution: fc000114 the following must be observed to prevent a fire hazard or other damages. Use only unleaded gasoline.Use of leaded gasoline will cause unrepairable damage to the catalytic converter. Never park this scooter in an area ...

  • Page 33

    4 instrument and control functions 4-9 1. Kick starter 1 push lock off in case of doubt and imperatively, when the handlebar presents a misalignment defect (after attempt of robbery, fall, important hit). Bring the scooter to the nearest yamaha dealer.Do not ride the scoo- ter. Do not try to straigh...

  • Page 34

    4 instrument and control functions 4-10 1. Open 2. Helmet holder 1. Fuel tank 2. Oil tank 1 2 2 1 eac72000 rear carrier 1 1. Rear carrier eac42301 seat to open the seat: 1. Insert the key in the lock and turn it as shown. 2. Lift the end of the seat up to open. To lock the seat: 1. Replace the seat ...

  • Page 35: Pre-Operation Checks

    5 pre-operation checks pre-operation checks ............................................................ 5-1.

  • Page 36: Pre-Operation Checks

    5 pre-operation checks 5-1 eae00000 owners are personally responsible for their vehicle’s condition. Your scooter’s vital function can start to deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it exposed to the elements). Any damage, fluid leak or loss of tire pressu...

  • Page 37: Pre-Operation Checks

    5 pre-operation checks 5-2 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. Warning the engine compartment and all the fan inlets need to stay cl...

  • Page 38

    6 operation and important riding points starting and warming up a cold engine ............................................ 6-1 starting a warm engine .................................................................... 6-2 starting the scooter ...........................................................

  • Page 39

    6 fau00372 operation and important riding points 6-1 pu s h lock off on 1. Starter lever (choke) warning euu81800 • before riding this scooter, become thoroughly familiar with all operating controls and their functions. Consult a yamaha dealer regarding any control or function that you do not thorou...

  • Page 40

    6 operation and important riding points 6-2 2 1 1. Start switch “ ” 2. Kick starter 4. Start the engine by pushing the star- ter switch while holding the front or rear brake lever, or by using the kick starter. 5. After starting the engine, turn back the starter (choke) to warming up position (about...

  • Page 41

    6 operation and important riding points 6-3 b a a b eaf21000 starting the scooter after warming up the engine: 1. Hold the brake lever with your left hand, and push the scooter off the centerstand while holding the rear passenger handle with your right hand. Then push the scooter forwards to fold th...

  • Page 42

    6 operation and important riding points 6-4 warning euu73802 1. Avoid hard or sudden braking. It may cause the scooter to skid or overturn. 2. Be sure to apply the brake carefully if leaning over to one side. Improper braking could lead to a skid. 3. Street car rails, metal plates on road constructi...

  • Page 43

    6 operation and important riding points 6-5 correct incorrect incorrect eaf40000 parking when parking the scooter, stop the engine and remove the ignition key. Warning euu63000 the muffler and exhaust pipe are hot. Park the scooter in a place where pedestrians or children are not likely to touch the...

  • Page 44

    7 periodic maintenance and minor repair recharging the battery .......................................... 7-16 replenishing the battery fluid ................................ 7-17 fuse replacement ................................................. 7-17 headlight .........................................

  • Page 45

    7 fau00462 periodic maintenance and minor repair 7-1 eah00400 periodic inspection, adjustment and lubrication will keep your scooter in the safest and most efficient condition pos- sible. Safety is an obligation of the scooter owner. The maintenance and lubrication schedule chart should be considere...

  • Page 46

    7 every initial 1,000 (600) n ° item 1 * fuel line 2 spark plug 3 air filter 4 * battery 5 * front brake (disc) 6 * rear brake (drum) 7 * wheels 8 * tires 9 * wheel bearings 10 * steering bearings checks and maintenance jobs • check fuel hoses and vacuum hose for cracks or damage • replace if necess...

  • Page 47: •

    7 periodic maintenance and minor repair 7-3 units: km (miles) n ° item 11 * chassis fasteners 12 centerstand 13 * front fork 14 * rear shock absorber 15 * carburetor 16 * autolube pump 17 final transmission oil 18 * v-belt checks and maintenance jobs • make sure that all nuts, bolts and screws are p...

  • Page 48

    7 periodic maintenance and minor repair 7-4 1. Spark plug gap 1 eah20202 spark plug inspection the spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. The ideal color on the white porcelain insulator around the...

  • Page 49

    7 periodic maintenance and minor repair 7-5 1. Drain plug 2. Oil filler plug 1 2 eah40603 replacing the transmission oil a. Place the scooter on a level surface and put it on the centerstand. The engine must be warm. B. Place a receptacle under the drain plug. Remove the oil filler cap and the drain...

  • Page 50

    7 periodic maintenance and minor repair 7-6 1 4 3 2 recommanded oil : yamalube 2-cycle oil or air-cooled, 2-stroke engine oil 1. Air filter case cover 1. Foam element 1 1 warning eah66700 air filter cleaning this air filter element should be cleaned at the specified intervals. It should be cleaned m...

  • Page 51

    7 periodic maintenance and minor repair 7-7 eah92300 carburetor adjustment the carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjustments should be left to a yamaha dealer who has the professional knowledge and experience to do so. Eai10801 autolube pump ad...

  • Page 52

    7 periodic maintenance and minor repair 7-8 @ eah90301 throttle cable adjustment adjust the throttle cable by turning the adjuster so that proper free play at the throttle grip is obtained. @ free play: 1.5 ~ 3.0 mm (0.06 ~ 0.12 in) 1. Loosen the lock nut. 2. Turn the adjuster in or out until specif...

  • Page 53

    7 periodic maintenance and minor repair 7-9 minimum tire tread depth (front and rear): 0.8 mm (0.031 in) too high too low ce-05us basic weight: with oil and full fuel tank maximum load*: cold tire pressure: rear front up to 90 kg (198 lb) *: 90 kg (198 lb) load ~ maximum load* 78 kg (172 lb) 152 kg ...

  • Page 54

    7 periodic maintenance and minor repair 7-10 1. Free play 1. Free play 1. Adjuster 2. To reduce free play 3. To increase free play 1 2 3 1 1 eah89600 rear brake adjustment the rear brake lever free play should be adjusted to 10 ~ 20 mm (0.4 ~ 0.8 in) at the brake lever end. Adjustment is accomplishe...

  • Page 55

    7 1 periodic maintenance and minor repair 7-11 front brake pads wear limit : 0.5 mm (0.019 in) 1. Wear limit 1. Wear indicator 2. Wear limit eah81401 checking the front brake pads and rear brake shoes a wear indicator is provided on each brake. This indicator allows checking of brake pad/shoe wear w...

  • Page 56

    7 periodic maintenance and minor repair 7-12 1. Lower brake fluid level eah88202 inspecting the brake fluid level insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the lower level and rep...

  • Page 57

    7 periodic maintenance and minor repair 7-13 eah83501 brake fluid replacement 1. Complete fluid replacement should be done only by trained yamaha ser- vice personnel. 2. Have a yamaha dealer replace the following components during periodic maintenance or when they are damaged or leaking. A. Replace ...

  • Page 58

    7 periodic maintenance and minor repair 7-14 eai32100 brake lever lubricate the pivoting parts. Recommended lubricant: yamalube 4 (10w30) or sae 10w30 motor oil eai30801* centerstand lubricate the pivoting parts. Check to see that the centerstand moves up and down smoothly. Recommended lubricant: ya...

  • Page 59

    7 periodic maintenance and minor repair 7-15 2. Operation check place the scooter on a level place. A. Hold the scooter in an upright po- sition and apply the front brake. B. Stroke the front fork up and down several times. Eai60301 steering inspection periodically inspect the condition of the steer...

  • Page 60

    7 periodic maintenance and minor repair 7-16 1. Battery 2. Battery breather hose a a 2 1 eai70801 battery check the level of the battery electrolyte and make sure that the terminals are tight. Add distilled water if the electrolyte level is low. Eai70002 recharging the battery. Disconnect the batter...

  • Page 61

    7 periodic maintenance and minor repair 7-17 + upper lower 1 2 1. Upper level 2. Lower level 1. Battery 2. Fuse 1 2 eai91802 fuse replacement 1. The fuse case is located under the seat. 2. If a fuse is blown, turn off the igni- tion switch and the switch of the cir- cuit in question. Install a new f...

  • Page 62

    7 periodic maintenance and minor repair 7-18 1. Bulb 2. Taillight lens 1 2 eai85800 headlight if the headlight beam adjustment or headlight bulb replacement is necessary, consult a yamaha dealer. Eaj10702* replacing the rear lamp bulb 1. Remove the taillight lens by removing the screws. 2. Push in t...

  • Page 63

    7 periodic maintenance and minor repair 7-19 eaj50002 troubleshooting although yamaha scooters receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, com- pression, or ignition systems can cause poor starting and loss of power. The t...

  • Page 64

    7 periodic maintenance and minor repair 7-20 eaj50700 troubleshooting chart warning euu66300 never check the fuel system while smoking or in the vicinity of an open flame. Fuel check no start open tank cap to check internal pressure negative normal have tank cap breather inspected add fuel (fuel ok)...

  • Page 65: Scooter Care  And Storage

    8 scooter care and storage cleaning ........................................................................................... 8-1 storage ............................................................................................. 8-2.

  • Page 66: Scooter Care And Storage

    8 scooter care and storage 8-1 7. Automotive-type wax may be applied to all painted and chrome-plated sur- faces. Avoid combination cleaner- waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the engine and let it idle for several minutes. 4. Once the ma...

  • Page 67: Scooter Care And Storage

    8 scooter care and storage 8-2 eak01500 b. Storage long term storage (60 days or more) of your scooter will require some preventive procedures to guard against deterioration. After thoroughly cleaning the scooter, prepare for storage as follows: 1. Drain the fuel tank, fuel lines, and carburetor flo...

  • Page 68: Specifications

    9 specifications specifications ................................................................................... 9-1.

  • Page 69: Specifications

    9 fau01038 specifications 9-1 specifications model cw50 dimensions: overall lenght 1740 mm (68.5 in) overall width 665 mm (26.2 in) overall height 1050 mm (41.3 in) seat height 745 mm (29.3 in) wheel base 1170 mm (46.1 in) minimum ground clearance 125 mm (4.9 in) minimum turning radius 1800 mm (70.9...

  • Page 70: Specifications

    9 specifications 9-2 tires: type tubeless size front 120/90-10 rear 130/90-10 manufacturer / model: front and rear michelin / dunlop reggae tl / trail max maximum load* 152 kg (335 lb) cold tire pressure: up to 90 kg front 100 kpa (1.00 kg/cm 2 , 15 psi) rear 125 kpa (1.25 kg/cm 2 , 18 psi) 90 kg lo...

  • Page 71: Consumer Information

    10 consumer information scooter identification ........................................................ 10-1 identification numbers record ......................................................... 10-1 key identification number ............................................................... 10-1 veh...

  • Page 72: Consumer Information

    10 consumer information 10-1 eaa60000 scooter identification zadi 1 1. Key identification number 1. Vehicule identification number 1 eaa60402 identification numbers record record the key identification number, vehicle identification number and engine serial number in the spaces provided for assistan...

  • Page 73: Consumer Information

    10 consumer information 10-2 1. Engine serial number 1 eaa70201 engine serial number the engine serial number is stamped into the transmission case. Euu00300 note: the first three digits of these numbers are for model identification; the remaining digits are the unit production number. Keep a record...

  • Page 74: Consumer Information

    10 consumer information eal00900 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 immediately inform the national highway traffic safety administration (nhtsa) in addition to notifying yamaha motor corp. U.S.A...

  • Page 75: Consumer Information

    10 consumer information eal00300 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 de...

  • Page 76: Consumer Information

    10 10-5 consumer information yamaha motor corporation, u.S.A. Riva limited warranty yamaha motor corporation, u.S.A. Hereby warrants that each new yamaha riva purchased from an authorised yamaha riva dealer in the continental united states will be free from defects in material and workmanship for th...

  • Page 77: Consumer Information

    10 10-6 consumer information warranty questions and answers q. What costs are my responsibility during the warranty period ? A. The customer’s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damage, and oil, oil filters, air filters, spa...

  • Page 78: Consumer Information

    10 10-7 consumer information yamaha extended service (y.E.S.) keep your yamaha protected even after your warranty ex- pires with genuine yamaha extended service (y.E.S.). • y.E.S. Is designed and administered by yamaha motor corporation to provide maximum owner satisfaction. You get uninterrupted fa...

  • Page 79: Yamaha

    10 y e s yamaha extended service 10-8 consumer information we urge you to act now. You’ll get the excellent benefits of trip coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your yamaha limited warranty expires. You can also save money : y.E.S...

  • Page 80: Index

    Index a acceleration ........................................... 6-3 air filter cleaning .................................... 7-6 autolube pump adjustment .................... 7-7 b battery ................................................. 7-16 brake fluid replacement ....................... 7-13 br...

  • Page 81: Index

    Index s safety information ....................... 1-2 accessories ......................................... 1-6 gasoline and exhaust gas ................... 1-7 loading ................................................ 1-5 loading and accessories ..................... 1-5 modification .................

  • Page 82: Protect Your Investment

    Printed in france 00.04 (e) protect your investment use genuine yamaha parts and accessories see your authorized yamaha dealer for a genuine yamaha service manual yamaha motor co., ltd..