YAMAHA JOG50R 2008 Repair Manual

Engine overheating (for CS50Z)EWA10400
s s
WARNING
●Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
●After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the his-
sing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
Wait until the
engine has cooled.Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.
The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.
Add coolant. (See NOTE.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
There is
leakage.
There is
no leakage.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.
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EAU37833
Matte color cautionECA15192
CAUTION:
Some models are equipped with
matte colored finished parts. Be
sure to consult a Yamaha dealer for
advice on what products to use
before cleaning the vehicle.Using a
brush, harsh chemical products or
cleaning compounds when clea-
ning these parts will scratch or
damage their surface. Wax also
should not be applied to any matte
colored finished parts.
EAU26091
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
detracts from the overall appearance
of a scooter. Frequent and proper
care does not only comply with the
terms of the warranty, but it will also
keep your scooter looking good,
extend its life and optimize its perfor-
mance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and
covers as well as all electrical
couplers and connectors, inclu-
ding the spark plug cap, are
tightly installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such pro-ducts onto seals, gaskets and
wheel axles. Always rinse the dirt
and degreaser off with water.
Cleaning
ECA10781
CAUTION:
●Avoid using strong acidic whe-
el cleaners, especially on spo-
ked wheels. If such products
are used on hard-to-remove
dirt, do not leave the cleaner on
the affected area any longer
than instructed. Also, tho-
roughly rinse the area off with
water, immediately dry it, and
then apply a corrosion protec-
tion spray.
●Improper cleaning can damage
plastic parts such as cowlings,
panels, windshields, headlight
lenses, meter lenses, etc. Use
only a soft, clean cloth or spon-
ge with mild detergent and
water to clean plastic.
●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 abrasive
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cleaning products, solvent or
thinner, fuel (gasoline), rust
removers or inhibitors, brake
fluid, antifreeze or electrolyte.
●Do not use high-pressure was-
hers or steam-jet cleaners sin-
ce they cause water seepage
and deterioration in the follo-
wing areas: seals (of wheel and
swingarm bearings, fork and
brakes), electric components
(couplers, connectors, instru-
ments, switches and lights),
breather hoses and vents.
●For scooters equipped with a
windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or scrat-
ching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not lea-
ve any marks. If the windshield
is scratched, use a quality
plastic polishing compound
after washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottle-
brush for hard-to-reach areas. Stub-
born 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 during winter are extremely
corrosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads.
NOTE:
Salt sprayed on roads in the winter
may remain well into spring.
1. Clean the scooter with cold water
and a mild detergent after the
engine has cooled down.
ECA10790
CAUTION:
Do not use warm water since it
increases the corrosive action of
the salt.
2. Apply a corrosion protection
spray on all metal, including
chrome- and nickel-plated, surfa-
ces 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 indu-
ced discoloring of stainless-steel
exhaust systems can be removed
through polishing.)
3. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal, inclu-
ding chrome- and nickel-plated,
surfaces.
4. Use spray oil as a universal clea-
ner to remove any remaining dirt.
5. Touch up minor paint damage
caused by stones, etc.
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6. Wax all painted surfaces.
7. Let the scooter dry completely
before storing or covering it.
EWA10940
s s
WARNING
●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 cornering behavior.
ECA10800
CAUTION:
●Apply spray oil and wax spa-
ringly and make sure to wipe
off any excess.
●Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
●Avoid using abrasive polishing
compounds as they will wear
away the paint.
NOTE:
Consult a Yamaha dealer for advice
on what products to use.
EAU26300
Storage
Short-term
Always store your scooter in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA10820
CAUTION:
●Storing the scooter in a poorly
ventilated room or covering it
with a tarp, while it is still wet,
will allow water and humidity to
seep in and cause rust.
●To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
Long-term
Before storing your scooter for seve-
ral months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Drain the carburetor float cham-
ber by loosening the drain bolt;
this will prevent fuel deposits
from building up. Pour the drai-
ned fuel into the fuel tank.
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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
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
times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap from
the spark plug, and then install
the spark plug and the spark plug
cap.EWA10950
s s
WARNING
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
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. Alter-
natively, turn the wheels a little
every month in order to prevent
the tires from becoming degra-
ded 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 warm pla-
ce [less than 0 ºC (30 ºF) or more
than 30 ºC (90 ºF)]. For moreinformation on storing the bat-
tery, see page 6-19.
NOTE:
Make any necessary repairs before
storing the scooter.
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Dimensions:Overall length:
1740 mm (68.5 in)
Overall width:
675 mm (26.6 in)
Overall height:
1065 mm (41.9 in)
Seat height:
770 mm (30.3 in)
Wheelbase:
1210 mm (47.6 in)
Ground clearance:
132 mm (5.19 in)
Weight:With oil and fuel:
CS50/CS50M: 81.0 kg (178.6 lb)
CS50Z: 84.0 kg (185.2 lb)
Engine:Engine type:
CS50/CS50M: Air cooled 2-stroke
CS50Z: Liquid cooled 2-stroke
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
49.0 cm
3(2.99 cu.in)
Bore x stroke:
40.0 x 39.2 mm (1.57 x 1.54 in)
Compression ratio:
CS50: 11.60:1
CS50M: 10,10 :1
CS50Z: 11.40 :1
Starting system:
Electric starter and kickstarterLubrication system:
Separate lubrication (Yamaha autolube)
Engine oil:Type:
YAMALUBE 2-cycle oil or 2-stroke engine
oil (JASO FC grade) or (ISO EG-C or EG-
D grade)
Engine oil quantity:
Quantity:
1.4 L (1.48 US qt) (1.23 Imp.qt)
Final transmission oil:Type:
SAE10W30 type SE motor oil
Quantity:
0.11 L (0.12 US qt) (0.10 Imp.qt)
CS50Z: Cooling system:Coolant reservoir capacity (up to the maxi-
mum level mark):
0.25 L (0.26 US qt) (0.22 Imp.qt)
Radiator capacity (including all routes):
0.91 L (0.96 US qt) (0.80 Imp.qt)
Air filter:Air filter element:
Wet element
Fuel:Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
5.5 L (1.45 US gal) (1.21 Imp.gal)
Fuel reserve amount
1.9 L (0.50 US gal) (0.42 Imp.gal)
Carburetor:Manufacturer:
GURTNERType x quantity:
PY 12 x 1
Spark plug(s):Manufacturer/model:
CS50-CS50Z: NGK/BR8HS
CS50M: NGK/BPR4HS
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clutch:Clutch type:
Dry, centrifugal automatic
Final transmission oil:Primary reduction system:
Helical gear
Primary reduction ratio:
52 x 13 (4.000)
Secondary reduction system:
Spur gear
Secondary reduction ratio:
CS50: 42 x 13 (3.231)
CS50M: 45 x 12(3.750)
CS50Z: 43 x 13 (3.308)
Transmission type:
V-belt automatic
Operation:
Centrifugal automatic type
Chassis:Frame type:
Steel tube underbone
Caster angle:
25.00 °
Trail:
80.0 mm (3.15 in)
SPECIFICATIONS
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Front tire:Type:Tubeless
Size: 110/70-12 47L
Manufacturer/model: CHENG SHIN TIRE / C922
Rear tire:Type:Tubeless
Size: 120/70-12 51L
Manufacturer/model: CHENG SHIN TIRE / C922
Loading:Maximum load:CS50/CS50M: 169 kg (372 lb)
CS50Z: 166 kg (366 lb)
(Total weight of rider, passenger, cargo and
accessories)
Tire air pressure (measured on cold
tires):
Loading condition: 0–90 kg (0–198 lb)
Front: 175 kPa (25 psi) (1.75 kgf/cm
2)
Rear: 200 kPa (28 psi) (2.00 kgf/cm
2)
Loading condition:
CS50/CS50M 90~169 kg (198~373 lb)
CS50Z 90~166 kg (198~366 lb): Front:175 kPa (25 psi) (1.75 kgf/cm
2) Rear:
225 kPa (32 psi) (2.25 kgf/cm
2)
Front wheel:Wheel type: Cast wheel
Rim size: 12xMT2.75
Rear wheel:Wheel type:Cast wheel
Rim size: 12xMT3.00
Front brake:Type:Single disc brake
Operation: Right hand operation
Recommended fluid: DOT 4
Rear brake:Type:Drum brake
Operation: Left hand operation
Front suspension:Type:Telescopic fork
Spring/shock absorber type: Coil spring/oil damper
Wheel travel: 70.0 mm (2.76 in)
Rear suspension:Type:Unit swing Spring/shock absorber type:
Coil spring/oil damper
Wheel travel: 60.0 mm (2.36 in)
Electrical system:Ignition system:DC. CDI
Charging system: AC magneto
Battery:Model:GT4L-BS
Voltage, capacity: 12 V, 4.0 Ah
Headlight:
Bulb type:Incandescence
Bulb voltage, wattage x quantity:Headlight:12 V, 35.0 W/35.0 W x 1
Tail/brake light: 12 V, 21.0 W/5.0 W x 1
Front turn signal light: 12 V, 10.0 W x 2
Rear turn signal light: 12 V, 10.0 W x 2
Meter lighting: 12 V, 1.2 W x 2
High beam indicator light: 12 V, 1.2 W x 1
Oil level warning light: LED x 1
Turn signal indicator light: 12 V, 1.2 W x 2
SPECIFICATIONS
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Coolant temperature warning light:LED x 1
Fuses:Main fuse:7.5 A
SPECIFICATIONS
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EAU26351
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 stolen.
KEY IDENTIFICATION NUMBER:
VEHICLE IDENTIFICATION NUMBER:
MODEL LABEL INFORMATION:
EAU26381
Key identification number
1. 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
1. 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 used to register your vehicle with
the licensing authority in your area.
1
ZAUM0070
CONSUMER INFORMATION
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EAU26490
Model label
1. Model label
The model label is affixed to the bot-
tom of the seat. (See page 3-10.)
Record the information on this label in
the space provided. This information
will be needed when ordering spare
parts from a Yamaha dealer.
CONSUMER INFORMATION
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