tires YAMAHA JOG50R 2004 Owners Manual

SAFETY INFORMATION.....................1-1
DESCRIPTION.....................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments .................2-3
INSTRUMENT AND CONTROL
FUNCTIONS........................................3-1
Main switch/steering lock .................3-1
Indicator lights ..................................3-1
Speedometer unit .............................3-2
Fuel gauge ........................................3-3
Clock .................................................3-3
Handlebar switches ..........................3-3
Front brake lever...............................3-4
Rear brake lever................................3-4
Fuel and 2 stroke engine oil
tank caps .......................................3-4
2-Stroke engine oil ...........................3-5
Kickstarter.........................................3-6
Seat...................................................3-6
Storage compartment.......................3-6
PRE-OPERATION CHECKS...............4-1
Pre-operation check list....................4-2
OPERATION AND IMPORTANT RIDING
POINTS................................................5-1
Starting a cold engine ......................5-1
Starting off ........................................5-1Acceleration and deceleration ..........5-2
Braking..............................................5-2
Engine break-in.................................5-2
Parking ..............................................5-2
PERIODIC MAINTENANCE AND
MINOR REPAIRS................................6-1
Periodic maintenance and
lubrication chart ............................6-2
Checking the spark plug ..................6-5
Final transmission oil ........................6-6
Coolant (only for liquid-cooled
models) ..........................................6-6
To check the coolant level ................6-7
Cleaning the air filter element ...........6-8
Adjusting the carburetor ...................6-9
Adjusting the throttle cable
free play .........................................6-9
Tires ..................................................6-9
Adjusting the front brake lever
free play .......................................6-11
Adjusting the rear brake lever
free play .......................................6-11
Cheking the front brake pads
and rear brake shoes ..................6-12
Checking the front brake fluid
level .............................................6-13
Changing the brake fluid ................6-13
Checking and lubricating the
cables ..........................................6-13Checking and lubricating the
throttle grip and cable .................6-14
Adjusting the autolube pump .........6-14
Lubricating the front and rear
brake levers .................................6-14
Checking and lubricating the
centerstand .................................6-14
Checking the front fork ...................6-15
Checking the steering.....................6-15
Checking the wheel bearings .........6-15
Replacing the headlight bulb or
a front turn signal light bulb ........6-16
Replacing a turn signal light bulb
or the tail/brake light bulb ...........6-16
Replacing the license plate light
bulb .............................................6-17
Battery ............................................6-17
Replacing the fuse ..........................6-18
Troubleshooting ..............................6-19
Troubleshooting chart .....................6-20
SCOOTER CARE AND STORAGE.....7-1
Care ..................................................7-1
Storage compartment.......................7-3
SPECIFICATIONS...............................8-1
CONSUMER INFORMATION.............9-1
TABLE OF CONTENTS
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EAU15603
Pre-operation check list
PRE-OPERATION CHECKS
4-2
4
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
Fuel• Refuel if necessary. 3-3, 3-4
• Check fuel line for leakage.
• Check oil level in oil tank.
2-stroke engine oil• If necessary, add recommended oil to specified level. 3-4, 3-5
• Check vehicle for oil leakage.
Transmission oil• Check oil level in transmission case.
• If necessary, add recommended oil to specified level.6-6
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Front brake• Replace if necessary. 6-11, 6-12, 6-13, 3-4
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
Rear brake• Lubricate cable if necessary.
3-4, 6-11, 6-12
• Check lever free play.
• Adjust if necessary.
• Make sure that operation is smooth.
Throttle grip• Check cable free play.
6-9, 6-14
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.
• Check for damage.
Wheels and tires• Check tire condition and tread depth.
6-9, 6-15
• Check air pressure.
• Correct if necessary.
Brake levers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.3-4, 6-11, 6-14
Centerstand• Make sure that operation is smooth.
• Lubricate pivot if necessary.6-14
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EAU17710
Periodic maintenance and lubrication chart
NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed
instead.
From 30000 km, repeat the maintenance intervals starting from 6000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
ODOMETER READING (x 1000 Km) ANNUAL
NOITEM CHEK OR MAINTENANCE JOB 1 6 12 18 24CHECK
1*Fuel line• Check fuel and vacuum hoses for cracks or damage.√√√√ √
• Check condition.
2
Spark plug• Clean and regap.√√
• Replace.√√
3Air filter element• Clean.√√• Replace.√√
4*Front brake• Check operation, fluid level and vehicle for fluid leakage.√√ √ √√ √• Replace brake pads. Whenever worn to the limit
5*Rear brake• Check operation and adjust brake lever free play.√√ √ √√ √• Replace brake shoes. Whenever worn to the limit
6*Brake hose• Check for cracks or damage.√√√√ √• Replace. Every 4 years
7*Wheels• Check runout and for damage.√√√√
• Check tread depth and for damage.
8*Tires• Replace if necessary.
√√√√ √
• Check air pressure.
• Correct if necessary.
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ECA10480
CAUTION
Make sure that the air filter ele-
ment is properly seated in the
air filter case.
The engine should never be
operated without the air filter
element installed, otherwise
the piston(s) and/or cylinder(s)
may become excessively worn.
7. Install the air filter case cover by
installing the screws.
8. Install the screw clamp and the
screws that fasten the air filter
case to the crankcase.
EAU21300
Adjusting the carburetor
The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, all car-
buretor adjustments should be left to
a Yamaha dealer, who has the neces-
sary professional knowledge and
experience.
EAU21370
Adjusting the throttle cable
free play
The throttle cable free play should
measure 2 ~ 5 mm (0,8 ~ 0,20 in) at
the throttle grip. Periodically check
the throttle cable free play and, if
necessary, adjust it as follows.
NOTE:
The engine idling speed must be
correctly adjusted before checking
and adjusting the throttle cable free
play.
1. Locknut
2. Adjuster
3. Free play
1. Loosen the locknut.
2. To increase the throttle cable free
play, turn the adjusting nut in
direction (a). To decrease the
throttle cable free play, turn the
adjusting nut in direction (b).
3. Tighten the locknut.
EAU33600
Tires
To maximize the performance, durabi-
lity, and safe operation of your vehi-
cle, note the following points regar-
ding the specified tires.
Tire air pressure
The tire air pressure should be chec-
ked and, if necessary, adjusted befo-
re each ride.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
21 b
a
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EWA10500
s s
WARNING
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperatu-
re of the tires equals the
ambient temperature).
The tire air pressure must be
adjusted in accordance with
the riding speed and with the
total weight of rider, passenger,
cargo, and accessories appro-
ved for this model.
EWA11200
s s
WARNING
Because loading has an enormous
impact on the handling, braking,
performance and safety characte-
ristics of your vehicle, you should
keep the following precautions in
mind.
NEVER OVERLOAD THE VEHI-
CLE! Operation of an overloa-
ded motorcycle may result in
tire damage, loss of control, or
severe injury. Make sure that
the total weight of rider, pas-
senger, cargo, and accessories
does not exceed the specified
maximum load for the vehicle.
Do not carry along loosely pac-
ked items, which can shift
during a ride.
Securely pack the heaviest
items close to the center of the
vehicle and distribute the
weight evenly on both sides.
Adjust the tire air pressure with
regard to the load.
Check the tire condition and air
pressure before each ride.
1. Depth
2. Side face
Tire inspection
The tires must be checked before
each ride. If the center tread depth
reaches the specified limit, if the tire
has a nail or glass fragments in it, or if
the sidewall is cracked, have a Yama-
ha dealer replace the tire immediately.
Minimum tire tread depth (front
and rear):
1.6 mm (0.06 in)
Tire air pressure (measured on cold
tires):
0~90 kg (0~198 lb):
Front:
175 kPa (24,90lb) (1,75 kgf/cm
2)
Rear:
200 kPa (28,44lb) (2,0 kgf/cm
2)
90~190 kg (198~419 lb) to maxi-
mum load:
Front:
175 kPa (24,90lb) (1,75 kgf/cm
2)
Rear:
225 kPa (32lb) (2,25 kgf/cm
2)
Maximum load*:
158,3 kg (348,4lb) CS50Z
161kg (255lb) CS50
* Total weight of rider, passenger,
cargo and accessories
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
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NOTE:
The tire tread depth limits may differ
from country to country. Always
comply with the local regulations.
Tire information
This model is equipped with tubeless
tires.
EWA10470
s s
WARNING
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
vehicle with excessively worn
tires decreases riding stability
and can lead to loss of control.
The replacement of all wheel
and brake related parts, inclu-ding the tires, should be left to
a Yamaha dealer, who has the
necessary professional know-
ledge and experience.
EAU22100
Adjusting the brake lever
free play
a. Free play
The brake lever free play should mea-
sure 2 ~ 5 mm (0,08 ~ 0,20 in) as
shown. Periodically check the brake
lever free play and, if necessary, have
a Yamaha dealer adjust it.
EWA10640
s s
WARNING
An incorrect brake lever free play
indicates a hazardous condition in
the brake system. Do not operatethe motorcycle until the brake sys-
tem has been checked or repaired
by a Yamaha dealer.
EAU22170
Adjusting the rear brake
lever free play
a. Free play
The brake lever free play should mea-
sure 5 ~ 10 mm (0,2 ~ 0,4 in) as
shown. Periodically check the brake
lever free play and, if necessary,
adjust it as follows.
j
k
Front tire:
Size:
110/70-12
Rear tire:
Size:
120/70-12 (Spain)
130/70-12
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
aa
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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.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.
7
SCOOTER CARE AND STORAGE
7-2
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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.
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 °C (30 °F) or more
than 30 °C (90 °F)]. For more
7
SCOOTER CARE AND STORAGE
7-3
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DimensionsOverall length
1740 mm
Overall width
675 mm
Overall height
1065 mm
Seat height
770 mm
Wheelbase
1210 mm
Ground clearance
132 mm
WeightWith oil and fuel
CS50 80.5 kg
CS50Z 83.7 kg
EngineEngine type
CS50 Air cooled 2-stroke
CS50Z Liquid cooled 2-stroke
Cylinder arrangement
Forward-inclined single cylinder
Displacement
49.2 cm3
Bore x stroke
40.0 x 39.2 mm
Compression ratio
CS50 10.20 :1
CS50Z 11.40 :1
Starting system
Electric starter and kickstarter
Lubrication system
Separate lubrication (Yamaha autolube)Type
YAMALUBE 2-cycle oil or 2-stroke engine
oil
Engine oil quantityQuantity
1.4 L
Transmission oilType
YAMALUBE 4 (10W30) or SAE10W30
type SE motor oil
Oil change quantity
0.10 L
Air filter element
Wet element
Fuel
Recommended fuel
Regular unleaded gasoline
Fuel tank capacity
5.5 L
CarburetorManufacturer
CS50 DELLORTO GURTNER
CS50Z DELLORTO
Type x quantity
CS50 PHVA 12 ZS/1 PY 12/1
CS50Z PHVA 12 ZS/1
Spark plug(s)Manufacturer/model
NGK/BR8HS
Spark plug gap
0.6-0.7 mm
Clutch type
Dry, centrifugal automatic
TransmissionPrimary reduction system
Helical gear
Primary reduction ratio
52/13 (4.000)
Secondary reduction system
Spur gear
Secondary reduction ratio
CS50 42/13 (3.230)
CS50Z 43 x 13 (3.310)
Transmission type
Single speed automatic
Operation
Centrifugal automatic type
ChassisCaster angle
25.00 degree
Trail
80.0 mm
Front tireSize
110/70-12 47L
Rear tireSize
120/70-12 51L 130/70-12 56L
Maximum load
CS50 161 kg
CS50Z 158 kg
Tire air pressure (measured on cold
tires)
Front
175 kPa
Rear
200 kPa
8
SPECIFICATIONS
8-1
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22-Stroke engine oil .....................................1-1
AAcceleration and deceleration ...................2-1
Adjusting the autolube pump ....................2-1
Adjusting the carburetor ............................2-2
Adjusting the front brake lever free play....2-3
Adjusting the rear brake lever free play .....3-1
Adjusting the throttle cable free play .........3-1
BBattery........................................................3-1
Braking .......................................................3-2
CCare............................................................3-3
Changing the brake fluid............................3-3
Checking and lubricating the cables .........3-3
Checking and lubricating the centerstand.3-4
Checking and lubricating the throttle
grip and cable ..........................................3-4
Checking the front brake fluid level ...........3-4
Checking the front fork ..............................3-5
Checking the spark plug ............................3-6
Checking the steering ................................3-6
Checking the wheel bearings ....................3-6
Cheking the front brake pads and
rear brake shoes ......................................4-1
Cleaning the air filter element ....................4-2
Clock ..........................................................5-1
Controls and instruments ..........................5-1
Coolant (only for liquid-cooled models) ...5-2
EEngine break-in ..........................................5-2
FFinal transmission oil .................................5-2Front brake lever ........................................6-1
Fuel and 2 stroke engine oil tank caps......6-2
Fuel gauge .................................................6-5
HHandlebar switches ...................................6-6
IIndicator lights ...........................................6-6
KKickstarter ..................................................6-8
LLeft view .....................................................6-9
Lubricating the front and rear brake
levers .......................................................6-9
M
Main switch/steering lock ..........................6-9
PParking .....................................................6-11
Periodic maintenance and lubrication
chart .......................................................6-12
Pre-operation check list ...........................6-13
RRear brake lever .......................................6-14
Replacing a turn signal light bulb or
the tail/brake light bulb ..........................6-14
Replacing the fuse ...................................6-14
Replacing the headlight bulb or a
front turn signal light bulb .....................6-14
Replacing the license plate light bulb......6-15
Right view ................................................6-15
SSeat ..........................................................6-16
Speedometer unit ....................................6-17
Starting a cold engine ..............................6-18
Starting off ...............................................6-19Storage compartment ..............................6-20
Storage compartment ................................7-1
TTires ...........................................................7-1
To check the coolant level .........................7-3
Troubleshooting .........................................8-1
Troubleshooting chart ................................9-1
INDEX
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