engine YAMAHA JOG50R 2005 User Guide

EAU15980
EWA10870
s s
WARNING
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 thoroughly
understand.
Never start the engine or ope-
rate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of cons-
ciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
For safety, always start the
engine with the centerstand
down.
EAU16560
Starting a cold engineECA10250
CAUTION
See page 5-2 for engine break-in
instructions prior to operating the
vehicle for the first time.
1. Turn the key to “*”, and when the
oil level warning light comes on,
turn it to “ON”.
ECA10240
CAUTION
If the oil level warning light does
not come on, have a Yamaha dealer
check the electrical circuit.
2. Close the throttle completely.
3. While applying the front or rear
brake, start the engine by pus-
hing the start switch or by pus-
hing the kickstarter lever down.
NOTE:
If the engine fails to start by pushing
the start switch, release the switch,
wait a few seconds, and then try
again. Each starting attempt should
be as short as possible to preserve
the battery. Do not crank the engine
more than 5 seconds on any oneattempt. If the engine does not start
with the starter motor, try using the
kickstarter.
ECA11040
CAUTION
For maximum engine life, never
accelerate hard when the engine is
cold!
EAU16760
Starting off
NOTE:
Before starting off, allow the engine to
warm up.
1. While pulling the rear brake lever
with your left hand and holding
the grab bar with your right hand,
push the scooter off the centers-
tand.
2. Sit astride the seat, and then
adjust the rear view mirrors.
3. Switch the turn signal on.
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.
5
OPERATION AND IMPORTANT RIDING POINTS
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EAU16780
Acceleration and
deceleration
The speed can be adjusted by ope-
ning and closing the throttle. To incre-
ase the speed, turn the throttle grip in
direction (a). To reduce the speed,
turn the throttle grip in direction (b).
EAU16791
Braking
1. Close the throttle completely.
2. Apply both front and rear brakes
simultaneously while gradually
increasing the pressure.
EWA10300
s s
WARNING
Avoid braking hard or suddenly
(especially when leaning over
to one side), otherwise the sco-
oter may skid or overturn.
Railroad crossings, streetcar
rails, iron plates on road cons-
truction sites, and manhole
covers become extremely slip-
pery when wet. Therefore, slow
down when approaching such
areas and cross them with cau-
tion.
Keep in mind that braking on a
wet road is much more difficult.
Ride slowly down a hill, as bra-
king downhill can be very diffi-
cult.
EAU16830
Engine break-in
There is never a more important
period in the life of your engine than
the period between 0 and 1000 km
(600 mi). For this reason, you should
read the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1000 km (600 mi). The various parts in
the engine wear and polish themsel-
ves to the correct operating clearan-
ces. During this period, prolonged
full-throttle operation or any condition
that might result in engine overhea-
ting must be avoided.
EAUT1110
0~150 km (0~90 mi)
Avoid operation above 1/3 throttle.
Stop the engine and let it cool for 5 to
10 minutes after every hour of opera-
tion. Vary the speed of the scooterfrom time to time. Do not operate it at
one set throttle position.
150~500 km (90~300 mi)
Avoid prolonged operation above 1/2
throttle.
500~1000 km (300~600 mi)
Avoid cruising speeds in excess of
3/4 throttle.
ECAT1010
CAUTION
After 1000 km (600 mi) of operation,
be sure to replace the final gear oil.
1000 km (600 mi) and beyond
Avoid prolonged full throttle opera-
tion. Vary speeds occasionally.
ECA10270
CAUTION
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
EAU17200
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
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OPERATION AND IMPORTANT RIDING POINTS
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EWA10310
s s
WARNING
Since the engine and exhaust
system can become very hot,
park in a place where pedes-
trians or children are not likely
to touch them.
Do not park on a slope or on
soft ground, otherwise the
vehicle may overturn.
5
OPERATION AND IMPORTANT RIDING POINTS
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EAU17280
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 inspection, adjustment, and
lubrication are explained on the follo-
wing pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a
general guide under normal riding
conditions. However, DEPENDING
ON THE WEATHER, TERRAIN, GEO-
GRAPHICAL LOCATION, AND INDIVI-
DUAL USE, THE MAINTENANCE
INTERVALS MAY NEED TO BE
SHORTENED.
EWA10320
s s
WARNING
If you are not familiar with mainte-
nance work, have a Yamaha dealer
do it for you.
EWA10330
s s
WARNING
This scooter is designed for use on
paved roads only. If this scooter is
operated in abnormally dusty,muddy or wet conditions, the air fil-
ter element should be cleaned or
replaced more frequently, otherwi-
se rapid engine wear may result.
Consult a Yamaha dealer for proper
maintenance intervals.
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PERIODIC MAINTENANCE AND MINOR REPAIR
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ODOMETER READING (x 1000 Km) ANNUAL
NOITEM CHEK OR MAINTENANCE JOB 1 6 12 18 24CHECK
9*Wheel bearings• Check bearing for looseness or damage.√√√√
10 *Steering bearings• Check bearing play and steering for roughness.√√ √ √√• Lubricate with lithium-soap-based grease. Every 24000 km
11 *Chassis fasteners• Make sure that all nuts, bolts and screws are
properly tightened.√√√√ √
12Centerstand• Check operation.
• Lubricate.√√√√ √
13 *Front fork• Check operation and for oil leakage.√√√√
14 *Shock absorber
• Check operation and shock absorber for oil leakage.√√√√
assembly
15 *Carburetor• Adjust engine idling speed.√√ √ √√ √
16 *Autolube pump• Check operation.
• Bleed if necessary.√√√√
17 *Cooling system• Check coolant level and vehicle for coolant leakage.√√√√ √• Change. Every 3 years
18Final transmission • Check vehicle for oil leakage.√√ √oil
• Change.√√√
19 *V-belt• Replace. Every 12000 km
20 *Front and rear brake
• Check operation.√√ √ √√ √
switches
21Moving parts and
• Lubricate.√√√√ √
cables
22 *Lights, signals • Check operation.
and switches• Adjust headlight beam.√√ √ √√ √
PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU19602
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 maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
To remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as
shown, with the spark plug
wrench included in the owner’s
tool kit.
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
vehicle is ridden normally).
NOTE:
If the spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnosesuch problems yourself. Instead, have
a Yamaha dealer check the vehicle.
2. Check the spark plug for electro-
de erosion and excessive carbon
or other deposits, and replace it if
necessary.
To install the spark plug
1. Distance between electrodes
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to spe-
cification.2. Clean the surface of the spark
plug gasket and its mating surfa-
ce, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4~1/2 turn past finger tight. Howe-
ver, the spark plug should be tighte-
ned to the specified torque as soon
as possible.
4. Install the spark plug cap.
Tightening torque:
Spark plug:
20 Nm (2,0 m•kgf, 14,6 ft•lbf)
Spark plug gap:
0,6 ~ 0,7 mm (0,24 ~ 0,27in)
Specified spark plug:
BR8HS/NGK
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EAU20060
Final transmission oil
1. Oil filler bolt
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
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Start the engine, warm it up by
riding the scooter for several
minutes, and then stop the engi-
ne.
1. Drain plug
2. Place the scooter on the centers-
tand.
3. Place an oil pan under the final
transmission case to collect the
used oil.
4. Remove the oil filler cap and
drain bolt to drain the oil from the
final transmission case.
5. Install the final transmission oil
drain bolt, and then tighten it to
the specified torque.
6. Add the specified amount of the
recommended final transmissionoil, and then install and tighten
the oil filler cap.
EWA11310
s s
WARNING
Make sure that no foreign
material enters the final trans-
mission case.
Make sure that no oil gets on
the tire or wheel.
7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
EAUS1200
Coolant (only for liquid-
cooled models)
The coolant level should be checked
before each ride. In addition, the coo-
lant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended final transmission
oil:
SAE30 motor oil.
Oil quantity:
0,11 L (0,0003 Imp.qt)
Tightening torque:
Final transmission oil drain bolt:
18 Nm (1,8 m•kgf, 13,2 ft•lbf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAUS1080
To check the coolant level
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion.
NOTE:
The coolant level must be chec-
ked on a cold engine since the
level varies with engine tempera-
ture.
Make sure that the vehicle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
1. Coolant level gauge window
2. Check the coolant level through
the check window.
NOTE:
The coolant should be between the
minimum and maximum level marks.
1. Coolant reservoir
3. If the coolant is at or below the
minimum level mark, remove the
front cowling by removing the
screws.
4. Open the reservoir cap, and then
add coolant to the maximum
level mark.
ECA10470
CAUTION
If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
If water has been used instead
of coolant, replace it with coo-
lant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the coo-
ling system will not be protec-
ted against frost and corrosion.
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possi-
ble, otherwise the effective-
ness of the coolant will be
reduced.
5. Close the reservoir cap, and then
install the front cowling by insta-
lling the screws.Coolant reservoir capacity:
0,380 L (0,00103 Imp.qt)
kbajdzc4050
30
10 2060
70
80
0:
6
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EAUS1090
Cleaning the air filter
element
The air filter element should be clea-
ned at the intervals specified in the
periodic maintenance and lubrication
chart. Clean the air filter element more
frequently if you are riding in unu-
sually wet or dusty areas.
1. Lid from the air filter box
2. Screw
3. Screw
1. Remove the screw clamp and the
screws that fasten the air filter
case to the crankcase.
1. Lid from the air filter box
2. Screws (x 3)
2. Remove the air filter case cover
by removing the screws.
3. Pull the air filter element out.
4. Clean the air filter element with
solvent, and then squeeze the
remaining solvent out.
1. The air filter
EWA10430
s s
WARNING
Use only a dedicated parts clea-
ning solvent. To avoid the risk of
fire or explosion, do not use gasoli-
ne or solvents with a low flash
point.
ECA10510
CAUTION
To avoid damaging the foam mate-
rial, handle it gently and carefully,
and do not twist or wring it.
5. Apply oil of the recommended
type to the entire surface of the
sponge material, and then sque-
eze the excess oil out.
NOTE:
The air filter element should be wet
but not dripping.
6. Insert the element into the air fil-
ter case.
Recommended oil:
Engine oil
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PERIODIC MAINTENANCE AND MINOR REPAIR
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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.
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PERIODIC MAINTENANCE AND MINOR REPAIR
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