2005 YAMAHA JOG50R engine

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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and never travel faster than
warranted by road and traffic
conditions.
• Always signal before turning or
changing lanes. Make sure that
other motorists can see you.
The posture of the operator and
passenger is important for proper
control.
• The operator should keep both
hands on the handlebar and
both feet on the footboard
during operation to maintain
control of the scooter.
• The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger foo-
trests.
• Never carry a passenger
unless he or she can firmly pla-
ce both feet on the passenger
footrests.
Never ride under the influence of
alcohol or other drugs.
This scooter is designed for on-
road use only. It is not suitable for
off-road use.Protective apparel
The majority of fatalities from scooter
accidents are the result of head inju-
ries. The use of a safety helmet is the
single most critical factor in the pre-
vention or reduction of head injuries.
Always wear an approved hel-
met.
Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impair-
ment of vision which could delay
seeing a hazard.
The use of a jacket, substantial
shoes, trousers, gloves, etc., is
effective in preventing or redu-
cing abrasions or lacerations.
Never wear loose-fitting clothes,
otherwise they could catch on
the control levers or wheels and
cause injury or an accident.
Never touch the engine or
exhaust system during or after
operation. They become very hot
and can cause burns. Always
wear protective clothing that
covers your legs, ankles, and feet.
Passengers should also observe
the above precautions.Modifications
Modifications made to this scooter
not approved by Yamaha, or the
removal of original equipment, may
render the scooter unsafe for use and
may cause severe personal injury.
Modifications may also make your
scooter illegal to use.
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, use
extreme caution when adding cargo
or accessories to your scooter. Use
extra care when riding a scooter that
has added cargo or accessories. Here
are some general guidelines to follow
if loading cargo or adding accessories
to your scooter:
Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit of
CS50Z 158kg (348,39lb), CS50 161kg
(355lb). When loading within this
weight limit, keep the following in
mind:
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Cargo and accessory weight
should be kept as low and close
to the scooter as possible. Make
sure to distribute the weight as
evenly as possible on both sides
of the scooter to minimize imba-
lance or instability.
Shifting weights can create a sud-
den imbalance. Make sure that
accessories and cargo are secu-
rely attached to the scooter before
riding. Check accessory mounts
and cargo restraints frequently.
Never attach any large or heavy
items to the handlebar, front fork,
or front fender. Such items can
create unstable handling or a
slow steering response.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this scooter. Since Yamaha cannot
test all other accessories that may be
available, you must personally be res-
ponsible for the proper selection, ins-
tallation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any
accessories.Keep the following guidelines in mind,
as well as those provided under “Loa-
ding” when mounting accessories.
Never install accessories or carry
cargo that would impair the per-
formance of your scooter. Care-
fully inspect the accessory befo-
re using it to make sure that it
does not in any way reduce
ground clearance or cornering
clearance, limit suspension tra-
vel, steering travel or control ope-
ration, or obscure lights or reflec-
tors.
• Accessories fitted to the hand-
lebar or the front fork area can
create instability due to impro-
per weight distribution or
aerodynamic changes. If
accessories are added to the
handlebar or front fork area,
they must be as lightweight as
possible and should be kept to
a minimum.
• Bulky or large accessories may
seriously affect the stability of
the scooter due to aerodyna-
mic effects. Wind may attempt
to lift the scooter, or the scoo-ter may become unstable in
cross winds. These accesso-
ries may also cause instability
when passing or being passed
by large vehicles.
• Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the fre-
edom of movement of the ope-
rator and may limit control abi-
lity, therefore, such
accessories are not recom-
mended.
Use caution when adding electri-
cal accessories. If electrical
accessories exceed the capacity
of the scooter’s electrical system
an electric failure could result,
which could cause a dangerous
loss of lights or engine power.
Gasoline and exhaust gas
GASOLINE IS HIGHLY FLAMMA-
BLE:
• Always turn the engine off
when refueling.
• Take care not to spill any gaso-
line on the engine or exhaust
system when refueling.
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• Never refuel while smoking or
in the vicinity of an open flame.
Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within
a short time. Always operate your
scooter in an area that has ade-
quate ventilation.
Always turn the engine off before
leaving the scooter unattended
and remove the key from the
main switch. When parking the
scooter, note the following:
• The engine and exhaust sys-
tem may be hot, therefore,
park the scooter in a place
where pedestrians or children
are not likely to touch these hot
areas.
• Do not park the scooter on a
slope or soft ground, otherwise
it may fall over.
• Do not park the scooter near a
flammable source (e.g., a kero-
sene heater, or near an open
flame), otherwise it could catch
fire.
If you should swallow any gasoli-
ne, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immedia-
tely. If any gasoline spills on your
skin or clothing, immediately
wash the affected area with soap
and water and change your clot-
hes.
EAU10360
Further safe-riding points
Be sure to signal clearly when
making turns.
Braking can be extremely difficult
on a wet road. Avoid hard bra-
king, because the scooter could
slide. Apply the brakes slowly
when stopping on a wet surface.
Slow down as you approach a
corner or turn. Once you have
completed a turn, accelerate
slowly.
Be careful when passing parked
cars. A driver might not see you
and open a door in your path.
Railroad crossings, streetcar
rails, iron plates on road cons-
truction sites, and manholecovers become extremely slip-
pery when wet. Slow down and
cross them with caution. Keep
the scooter upright, otherwise it
could slide out from under you.
The brake lining could get wet
when you wash the scooter. After
washing the scooter, check the
brakes before riding.
Always wear a helmet, gloves,
trousers (tapered around the cuff
and ankle so they do not flap),
and a bright colored jacket.
Do not carry too much luggage
on the scooter. An overloaded
scooter is unstable. Use a strong
cord to secure any luggage to the
carriers. A loose load will affect
the stability of the scooter and
could divert your attention from
the road.
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EAU10460
Main switch/steering lock
The main switch/steering lock con-
trols the ignition and lighting systems,
and is used to lock the steering. The
various positions are described
below.
EAU10630
ON
All electrical systems are supplied
with power, and the engine can be
started. The key cannot be removed.
EAU10660
OFF
All electrical systems are off. The key
can be removed.
EAU10670
*
The 2-stroke engine oil level warning
light should come on. (See page 3-1.)
EAU10680
LOCK
The steering is locked, and all electri-
cal systems are off. The key can be
removed.
T
o lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF”
position, and then turn it to
“LOCK” while still pushing it.
3. Remove the key.
T
o unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
EWA10060
s s
WARNING
Never turn the key to “OFF” or
“LOCK” while the vehicle is
moving, otherwise the electrical
systems will be switched off, which
may result in loss of control or an
accident. Make sure that the vehi-
cle is stopped before turning the
key to “OFF” or “LOCK”.
EAU10980
Indicator lights
1. Turn signal indicator lights “b”
2. High beam indicator light “j”
3. Oil level warning light “z”
4. Coolant temperature warning light “y”
j
d
z
c4050
30
10 2060
70
80
0
y
00000.0
23:08TOTALExF
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EAU11030
Turn signal indicator lights “c” and
“d”
The corresponding indicator light flas-
hes when the turn signal switch is
pushed to the left or right.
EAU11080
High beam indicator light “j”
This indicator light comes on when
the high beam of the headlight is swit-
ched on.
EAU11130
2-stroke engine oil level warning
light “z”
This warning light comes on when the
2-stroke engine oil level is low.
The electrical circuit of the warning
light can be checked according to the
following procedure.
1. Turn the key to “ON”.
2. Shift the transmission into the
neutral position.
3. If the warning light does not
come on, have a Yamaha dealer
check the electrical circuit.
ECA11570
CAUTION
Do not operate the motorcycle until
you know that the 2-stroke engine
oil level is sufficient.
NOTE:
Even if the 2-stroke engine oil level is
sufficient, the warning light may flic-
ker when riding on a slope or during
sudden acceleration or deceleration,
but this is not a malfunction.
EAU11430
Coolant temperature warning light
“y”
This warning light comes on when the
engine overheats. When this occurs,
stop the engine immediately and
allow the engine to cool.
ECA10020
CAUTION
Do not operate the engine if it is
overheated.
EAUM1090
Speedometer unit
1. Speedometer unit
2. Fuel gauge
3. Clock
4. Odometer (TOTAL/TRIP)
5. “TRIP” button
The speedometer unit is equipped
with a speedometer, an odometer and
a tripmeter. The speedometer shows
riding speed. The odometer shows
the total distance traveled. The trip-
meter shows the distance traveled
since it was last set to zero.
Pushing the reset button switches the
display between the odometer mode
“TOTAL” and the tripmeter mode
“TRIP”. To reset the tripmeter, enter
the “TRIP” mode, and then hold down
j
d
z
c4050
30
10 2060
70
80
0
y
00000.0
23:08TOTALExF
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EAU12500
Horn switch “a”
Press this switch to sound the horn.
EAU12700
Start switch “START”
1. Start switch
Push this switch while applying the
front or rear brake to crank the engine
with the starter.
ECA10050
CAUTION
See page 5-1 for starting instruc-
tions prior to starting the engine.
EAU12900
Front brake lever
The front brake lever is located on the
right handlebar grip. To apply the
front brake, pull this lever toward the
handlebar grip.
EAU12950
Rear brake lever
The rear brake lever is located on the
left handlebar grip. To apply the rear
brake, pull this lever toward the hand-
lebar grip.
EAU13200
Fuel and 2-stroke engine oil
tank caps
1. Fuel tank cap
2. Engine oil tank cap
The fuel tank cap and the 2-stroke
engine oil tank cap are located under
the seat. (See page 3-6.)
Fuel tank cap
To remove the fuel tank cap, turn it
counterclockwise, and then pull it off.
To install the fuel tank cap, turn it
clockwise.
j
k
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2
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2-stroke engine oil tank cap
To remove the 2-stroke engine oil tank
cap, pull it off.
To install the 2-stroke engine oil tank
cap, push it into the oil tank opening.
EWA10140
s s
WARNING
Make sure that the fuel and 2-stro-
ke engine oil tank caps are properly
installed before riding the scooter.
EAU13220
Fuel
1. Refill pipe
2. Fuel level
Make sure that there is sufficient fuel
in the tank. When refueling, be sure to
insert the pump nozzle into the fuel
tank filler hole and to fill the tank to
the bottom of the filler tube as shown.
EWA10880
s s
WARNING
Do not overfill the fuel tank,
otherwise it may overflow
when the fuel warms up and
expands.
Avoid spilling fuel on the hot
engine.
ECA10070
CAUTION
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfa-
ces or plastic parts.
EAU13270
Your Yamaha engine has been desig-
ned to use regular unleaded gasoline
with a research octane number of 91
or higher. If knocking (or pinging)occurs, use a gasoline of a different
brand or premium unleaded fuel. Use
of unleaded fuel will extend spark
plug life and reduce maintenance
costs.
EAU13460
2-stroke engine oil
Make sure that there is sufficient oil in
the 2-stroke engine oil tank. Add the
recommended 2-stroke engine oil if
necessary.
NOTE:
Make sure that the 2-stroke engine oil
tank cap is properly installed.
Recommended oil:
Yamalube 2 or equivalent 2-stroke
engine oil (JASO grade “FC”, or
ISO grades “EG-C” or “EG-D”)
Oil quantity:
1,4L (0,31 US qt)(1,23 Imp.qt)Recommended fuel:
REGULAR UNLEADED GASOLINE
ONLY
Fuel tank capacity:
5,5L (1,21 US gal) (4,8Imp.gal)
Fuel reserve amount:
1,9L(0,42US gal) (1,67Imp.gal)
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