Yamaha BWS CW50L Service Manual

1999 - 2002MOTORCYCLESERVICE MANUALModel : CW50L, CW50M, CW50N, CW50P4RW281972K00*4RW281972K00*

I TRBLCHAPTER 8.TROUBLESHOOTINGSTARTING FAILURE/HARD STARTING ... G-8FUEL SYSTEM ...

ITRBL I G - 8 I STARTING FAILURE/HARD STARTING/ TRBL ep ISTARTING FAILURE/HARD STARTING SHTG _ POOR IDLE SPEED PERFORMANCE SHTG --TROUBLESHOOTING COMP

I L I I T. LTRBL _ G 9 FAULTY AUTOMATIC SHTGPOOR MEDIUM AND HIGH SPEED PERFORMANCE SHTG • = °POOR MEDIUM AND HIGH SPEED PERFORMANCE FAULTY AUTOMATIC (

ITRBLIINSTABLE HANDLING/IMPROPER KICKING/FAULTY BRAKE I" FAULTY SIGNALAND LIGHTING SYSTEM iTRBLIMPROPERKICKING INSTABLEHANDLINGSLIPPING INSTABLE

FAULTY SIGNAL AND LIGHTING SYSTEM/OVERHEATING ITRBL ITRBLFlasher winks slower Horn is inoperative• Faulty flasher relay • Faulty battery• Insufficient

IG-12 IWIRING DIAGRAM _ C,D.I Magneto® _(_c,_ _ C.D.I UnitIgnition coil_:: [_ @ Spark plugi8w @ Main switch8 _!_] -- r- ... @Fuser_ _::1_ _ Battery..

Yamaha Motor Canada Ltd.480 Gordon Baker RoadToronto, ON M2H 3B4

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IsPEc_'1tA-131 IsPEc_1CHAPTER 2.SPECIFICATIONSGENERAL SPECIFICATIONS ... A-14MAI

GENERAL SPECIFICATIONS I SPEc /'(_'1 IA-41 GENERAL SPECIFICATIONS I SPEC /(_i'SPECIFICATIONS Model CW50GENERAL SPECIFICATIONS Clutch ty

I P'=c IA-lSI MAINTENANCE SPECIFICATIONS I SPEc /'_'1Model CW50 MAINTENANCESPECIFICATIONSElectrical: ENGINEIgnitionsystem CDI Model CW5

MAINTENANCE SPECIFICATIONS IsPECIA-161 MAINTENANCE SPECIFICATIONSModel CW50 CHASSISCrankshaft: Model CW50B__:J Steering system:Steeringbearingtype Bal

M.,.TE.A.OE.PEC,..C..,O.SIs Ec B-1I M.,.TE...CES.EC,F,C.T,O.SISPECELECTRICAL Model CW50Model CW50 Battery:Voltage: 12 V Capacity 12V, 4 AhIgnition sys

CA..E.OUT,.OIS" clPIIB'2 CA°LE.O°T,.OIS"EclP I_3) Rim [] Do not cover the frame number. _) Handlebar [] The right handlebar switch lead

OASLERO°T,NOISPECl;]IB'3 Is'c(_) Choke cable [] Tie the choke cable,throttle cable, rear brake cable, and speedometer(_) Throttle cable cabl

IA-21NOTICEThis manual was written by the MBK INDUSTRIE primarily for use by YAMAHA dealers and theirqualified mechanics. It is not possible to put an

I INSPBEI I- ICHAPTER 3.PERIODIC INSPECTION AND ADJUSTMENTINTRODUCTION ...

INTRODUCTIONIPERIOOIC MAINTENANCEI I INSP I I I INSP ILUBRICATION INTERVALS ADJ IF_ B - 7 COVERS _ _PERIODIC INSPECTION AND ADJUSTMENT _ I __ COVERSIN

COVERS I INSP_ _ffr_ I B-8 I COVERS I INSP_ _1t_ _ 8. Remove: ___ 4. Install:, _ • Footrest board (D • Front panel (D• Bottom cover (_) • Main switch

I'"sP II I'"sP IENGINE IDLE SPEED ADJUSTMENT _ _ B - 9 THROTTLE CABLE FREE PLAY ADJUSTMENT ___ ENGINE IDLE SPEED ADJUSTMENT MENTij

IINSPSPARK PLUG INSPECTION IIB-101 ISPARK PLUG INSPECTION /_ .4 AUTOLUBE PUMP AIR BLEEDING1. Remove: _ _ 1, Remove:• Spark plug ;_ ,i,/_ " Fan co

I I'"sPIENGINE OIL LEVEL INSPECTION B - 11 TRANSMISSION OIL REPLACEMENT _ _ENGINE OIL LEVEL INSPECTION _ _ " ' __ TRANSMISSION OIL

FRONT BRAKE LEVER FREE PLAYADJUSTMENT/I II I IAIR FILTER ELEMENT CLEANING _ _ B - 12 BRAKE PAD INSPECTION _ _r_-J-_ AIR FILTER ELEMENT CLEANING CHASSI

"E'"S"OE''"SPEC"O"'I'"SPII I I'"sp [BRAKE FLUID LEVEL INSPECTION -A_ R_ B =13 AI

I'"sP I I'"sp ISTEERING HEAD ADJUSTMENT VT_W_,_I-I_.II_,[¢!1. Check: Proper loading of your scooter is Important• Steering assembl

TIRE INSPECTION/WHEEL INSPECTION/ I INSP I I I CABLE INSPECTION AND LUBRICATION/ I INSP ICABLE INSPECTION AND LUBRICATION _ _ B - 15 REAR SHOCK ABSORB

IA-31HOW TO USE THIS MANUAL ® ® ILLUSTRATEDSYMBOLSCONSTRUCTION OF THIS MANUALThis manual consists of chapters for the main categories of subjects. (Se

IINSPII I BATTERYINSPECTIONIIINSP IBATTERY INSPECTION ADJ _ B - 1 6 FUSE INSPECTION _ELECTRICAL :CAgTiONiI_ I t _ _'_ /_) BATI'ERY INSPECTIO

OS'"SPEOT'O"'I'"SPI I'"sp IHEADLIGHT BEAM ADJUSTMENT _ _ C - 1 I****************************************

I lc-l ICHAPTER 4.ENGINE OVERHAULENGINE REMOVAL ... C-5COVER REMOVA

E.O,.E.EMOV.LIE"O''1 IC'I E.O,.E.EMOV.LENGINE OVERHAUL CABLES,LEADSANDHOSESENGINE REMOVAL 1. Remove:• Oil hose (_ on oil pump side

_rJ. 1. Place a suitable stand under the frame.REAR WHEEL_-_ 2, Remove: 1, Remove:• Left pillion footrest • Rear wheel nut• Rear shock absorber bolt (

E.O,NEO,..SSE.SLYIE"O_'1IC'_] E.O,NEO,SASSE.BLYIE"O''12. Remove: PRIMARYSHEAVE__)(__) •Piston pin(_ __ 1. Remove:• Pisto

l..olo,..l2. Remove:_/ •o,utc,housing® _ ________ •Spacer®\ _._" /_ 2" Remove: _/_ ° Bearing _• Secondary sheave (_) _ - Washer (_• Crankcas

I..o"-.I c-91 I'"° "1_ 2. Remove: sary, loosen one screw as much as required to• Rotor (_ level the tool body.?_ • Woodruff keyL /

A-4 IINDEXSPECIFICATIONSPERIODIC INSPECTION I _ IAND ADJUSTMENT I '"sPENGINEOVERHAULCARBURETIONCHASSISELECTRICALTROUBLESHOOTING

I..o Ic-01 I..o°.-I__ CYLINDER HEAD • Piston wall1. Eliminate: Wear/Scratches/Damage --*Replace.• Carbon depositsUse a rounded scraper (_)NOTE:Take ca

If out of specification, replace piston andpiston rings as a set. (_,X'%I Standard Limit3rd step: Top 0.15 ~ 0.30 mm 0.70 mmCalculate the piston-

,.SPECT,O...O.EP...IC'121 ,.SPECT,O...O.EP.,.IE"OKICK STARTER AUTOLUBE PUMP(_ 1. Inspect: Wear or an internal malfunction may cause the• Kic

• Free movement oClutch housing inner surfaceInsert the collar (_) into the primary sliding Oil/Scratches _ Remove.sheave 0, and check for free moveme

,.s..c.,o...o...,.I..o"-.IIc- 41 ..o,.. ..o.o,us...T °"12. Measure: ENGINE ASSEMBLY AND ADJUSTMENT• V-belt width @ CRANKCASE AND CRANKSHAF

• Crankshaft installation tool C), (_, (_), @To protect the crankshaft against scratches Crankshaft installation tool :and to facilitate the engine as

..O,...SS...'_'"O'O'OS'M'"'I'"" °,-IIc-_6l ..o...ss..._..o.o,os...I,.o"-I_Fan @Ga

E"O'"EASSE"B'Y'"O'O'°ST"E"TIE"o O11 E.O,.E.SS. LY..OAOJ°STME.T5. Install: TRANSMISSION_)(_

_.O..E,SSE.LYA.O,O,OST.E.T_ 0-21 E"O'"EASS_--_'"O,O,0ST.E.TIE"O_ ITRANSMISSION STARTERSYSTEM1. Apply: (_ Collar _ Plate•

E"O"E'SSE"BLY'"O'O'0STME"TI 1I0 3 E.O.E,,,EMLY,.O,O,USTM .TIE"O I,_ , STARTER SYSTEM PRIMARY AND SEC

1I1 II!I[!

E"O'"E'SSE"O_'"O'O'UST"E"TI--__-] O''J E"O'"E'SSE''YA&q

E.O..E.SSE.B..O.O,OST"E"TIE"OI'IO'SI UST"E"TI "O1 '18. Instalh 5. Install:I • Dowel pin • V-beltI XJ _ •

_ 9. Install: PISTON, CYLINDER AND CYLINDER HEAD• Fan O _ Carburetor joint _ Cylinder gasketReed valve @ Piston ringScrew (fan): I _ Gasket @Piston6.5

E.O,.E.'SE.BLY'"O'O'UST E"TD' I E"O'"E'SSEMBLYA"O'O'OST"E"TIE"oI

E"O'"E'SSE"B,.O,O,OSTME.TIE"O 10"8 E"O'"E'SSE B ,.O,O,OSTME.T8. Install: =j _, 5. Tighten:• Air

plytU

L_.B_ I Io-_l Ic R"OICHAPTER 5.CARBURETIONCARBURETOR ...

CARBURETOR REMOVAL(_ Carburetor top _ Pilot jet 1. Remove:Gasket _ Needle jet • Covers and footrest boardThrottlevalvespring _ Needlevalve Referto&quo

__ 4. Remove: _j,j,j 4. Check:• Throttle stop screw C) • Throttle valve 0• Spring (throttle stop screw) Wear/Damage --* Replace.• Air screw (_)• Sprin

C,.BO.ETO.IC'"B0IID'I'I C,.BO.ETO.IOA"B013. Install:NOTE: _ • CarburetorThe float arm should be resting on the needle NOTE:va

I GENCHAPTER 1.GENERAL INFORMATIONSCOOTER IDENTIFICATION ... A-8VEHICLE IDENTIFICA

I [ ] FUELCOCK/ CARB IFUELCOCK/ CARB D-15REEDVALVE REEDVALVEFUELCOCK iNSPECTiON1. Check:INSPECTION •Carburetorjoint1. Stop the engine, Damage/Cracks _

_v,,wIC'R_0 IID'_sl I_'_ 01INSTALLATIONTOinstall the reedvalve reverse the "REMOVAL"procedure. Note the following points.1. I

I ...!wuu--M--_m.mmm.,J_Ipv v

CHAPTER 6.CHASSISFRONT WHEEL ... E-4REMOVAL ...

.O.TW.EELIC"'SI E-'] F.O.T..EELIO"'SCHASSIS ,_ REMOVALFRONTWHEEL 1.Remove:_) Axle _ Oil seal /!_FrontcaliperfixingDbolts• Fr

F--.EELIC"'SI E-SI ..O.,,.,.EIC"'SINSTALLATION FRONTBRAKENOTE:Reverse the =Removal" procedure. _ Disc _ Pad spring Be sure to

MASTER CYLINDER DISASSEMBLY _'!!w-'_;l_ _[dlMaster cylinder Q Bolt NOTE: • Disc brake components rarely require dis-® Master cylinder piston

F.O.TB.,KE E'I .O.TB,,KEIC"'S4. Install: ...oBrake pads Removal steps:• Pad spring

.O.TB,,KEIC"'S 1E-81 F.O.TB.,KIC"'S_ 4. Remove: _ 3. Check:o Master cylinder dust boot 0 , Brake hose (_)• Master cylinder kit (_

IGE" I 1 I°E"SCOOTER IDENTIFICATION INFO A - 8 IMPORTANT INFORMATION INFOINFORMATION ALL REPLACEMENT PARTS1. Use only genuine parts for all

.O.TB .EIC"'S E-'] .O.TB .EIC"'SI2. Install: _'_" 1. Install:• Brake caliper ___o • Master cylinder (_)I<_1 Bo

.--.EELIC--I IE'101 --W.EELIC"'SREARWHEEL REMOVAL1. Remove:Rear wheel ass'y _ O-ring _ Wear indicator • Muffler ass'yTire _ B

IC"ASIIE'111 .E,.W,EE"wheeearn0s Br keshoesORefer to the section "FRONT WHEEL IN- • Return spring (_)SPECTION". NOTE:4. Check

REARWHEEL I CHAS (_r'(g] IE-121 FRONTFORK I CHAs (_).u,,.rWh.--, ..ONTFO.105 Nm (10.5 m.kg, 76 ft.lb) _ Steering bracket @ Inner fork tube (right

ICH' ®lIE-131 FRONTFORKREMOVAL _ DISASSEMBLY1. Remove:Securely support the scooter with a stand • Rubber plug (Dunder the engine. • Circlip (_•

.O.TO.KIC"'SI[E-I'] F.O.TO.KINSPECTION 3. Install:1. Check: _i_ • Copper washer(New),^,• Inner fork tube and fork components • Drain b

STEERING HEAD AND HANDLEBAR _ IE-151 STEERING HEAD AND HANDLEBARSTEERING HEAD AND HANDLEBAR STEERING HEAD AND_) HandlebarNut HANDLEBAR_) Bolt REMOVALG

Ic.As IE-lel STEE.,.O.EAOA.O...OLE ..10. Remove: JA **... ******************************************• Securing nut Bearing race replacement step

IC"'S I[ S.EE.,.O.E.O..O...O.EB..C"'S3. Install: 9. Clamp:• Steering shaft • Speedometer cable• Upper bearing race (Top) (D ° Fro

RE,RS.OCK,BSOR_ERIC"'S_IIF'2I c.,s_1REAR SHOCK ABSORBERREMOVAL1. Place the scooter on its centerstand2. Remove:• MoleRefer to "COV

I°E"I IGE"IIMPORTANT INFORMATION/SPECIAL TOOLS INFO _ A" 9 J SPECIAL TOOLS INFOCIRCLIPS Flywheel magneto pullercare,u,, e- 08 0-019[_

+

IELEC_1 I F-S IE_EC_ ICHAPTER 7.ELECTRICAL COMPONENTSELECTRICAL COMPONENTS ... F-6SW

E'ECT..C.LCO.PO.E.TSIE' c IF'6I SW,TO.,.SPEOT,O.IE'EcELECTRICAL SWITCHINSPECTION"0" SWITCH INSPECTIONELECTRICAL COMPONEN

SW,.C"'"S"ECT'O"IE'EC-------I F'_I SW..C.,.S.ECT,O._SWITCH CONTINUITY INSPECTION _ Horn switchRefer to "S

c,.co,To..o...IELEc'11 -8 C,.CU,TO,AO..MIE'ECJCIRCUIT DIAGRAM _ C.D.I Magneto _ Left front flasher lightC.D.I Unit _ Right front flasher lig

.O.,T.O...OST..T,.OSYSTE.IE'EC------I1_"9I ,O.,T,O...OST..T,.OSYSTEMIE'EC" IIGNITION AND STARTING SYSTEM IGNITIONANDSTARTINGSYSTEM

IE'Ec [F-10I IELEcTROUBLESHOOTING 3.Sparkplugcapresistance:I THE STARTING SYSTEM DOES NOT WORK • Disconnect the spark plug cap.(NO SPARK OR IRREG

'O"'T'O"'"OSTA.T,.OSYSTE.IE'EC------I[F-11 'O"'T'O"'"OST..T,.OSYSTE-0- I sT

STARTER MOTOR4. Starter relay: (_ O-ring• Disconnect the Blue/White lead from the _ Brushwire harness. _ Armature coil• Connect the (-) _ terminal of

IGENSPECIAL TOOLS I'NFO _1_1 IA _ol I- I.FO_1Ring nut wrench90890-01268 _ ,_ _90890-01403 _)FOR CHASSIS SERVICEDamper rod holder T-Handle90890o01

,ON,T,ON.NOST.RT,NOSYSTEMIE'Ec ['131 ,ON,T,ON.NOST.RT,NOSYSTE.IE' CREMOVAL _ 5. Measure: J@/_ 1. Inspect: - Brush length @• Commutator

C...O,.OS*STEMIE'ECIF'141 C...O,.OS*STE.CHARGINGSYSTEM TROUBLESHOOTINGCIRCUITDIAGRAM I THEBATTERYISNOTCHARGED INOTE:• Remove the following p

C.A.O,.OSY.TEM1'151 .,O.T,.OSYSTE.IE'"c4.Charging coil resistance LIGHTING SYSTEM• Disconnect the CDI magneto coupler from ,_L-_ _ CIRC

TROUBLESHOOTING LIGHTING SYSTEM INSPECTION1. Headlight, headlight indicator or meter light do not work.I THE HEADLIGHT, HEADLIGHT INDICATOR, TAlL LIGH

',°.T,.°S*STEMIG'II S'°"A'S*'TE"IELECI3. The tail light does not work. SIGNAL SYSTEM1. Bulb and socket j NO CONTINU

S,O..LSYSTE.IELECG'2 ..O.ALSYSTEMIELECTROUBLESHOOTING SIGNALSYSTEMCHECK1. Horn does not soundI FLASHER LIGHTS, BRAKE LIGHT, "OIL" WARNI

S,O..LSYSTEMIE'Ec G-3I S,O..LSYSTEMIE'Ec2. The tail light does not work. 3. Flasher does not workI1. I 1. "TURN" switch INCORRECTR

S.O.ALSY.TE.IE'EC [G'41 S,O.ALSYSTE.I'Eo-----J,_ 4. The "OIL" indicator light does not work.4.Voltage I 1.Bulbandsocket ImFla

A......I ,,ii....u lull=c,-Ju :