2008 YAMAHA JOG50R engine

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.
EAU17212
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10310
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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.
ECA10380
CAUTION:
Never park in an area where there
are fire hazards such as grass or
other flammable materials.
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
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WARNING
If you are not familiar with mainte-
nance work, have a Yamaha dealer
do it for you.
EWA10330
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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.
PERIODIC MAINTENANCE AND MINOR REPAIR
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PERIODIC MAINTENANCE AND MINOR REPAIR
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ODOMETER READING
ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1000 km 6000 km 12000 km 18000 km 24000 kmCHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
• Check tread depth and for damage.
8*Tires• Replace if necessary.
√√√√ √
• Check air pressure.
• Correct if necessary.
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 (14000 mi)
11 *Chassis fasteners• Make sure that all nuts, bolts and screws are
properly tightened.√√√√ √
12Front brake lever
• Lubricate with silicone grease.√√√√ √
pivot shaft
13Rear brake lever
• Lubricate with lithium-soap-based grease.√√√√ √
pivot shaft
14Centerstand• Check operation.
• Lubricate.√√√√ √
15 *Front fork• Check operation and for oil leakage.√√√√
16 *Shock absorber
• Check operation and shock absorber for oil leakage.√√√√
assembly
17 *Carburetor• Adjust engine idling speed.√√√√√ √
18 *Autolube pump• Check operation.
• Bleed if necessary.√√√√
19Transmission oil• Check oil level.√√√√√ √• Change.√√
20 *Cooling system• Check coolant level and vehicle for coolant leakage.√√√√ √
• Change. Every 3 years
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EAUM1250
Panel A
T
o remove the panel
1. Open the storage compartment.
(See page 3-11.)
2. Remove the screw, and then take
the panel off.
1. Screw
2. Panel
To install the panel
1. Place the panel in the original
position, and then install the
screw.
2. Close the storage compartment.
EAU19621
Checking the spark plug
1. Spark plug gap
The spark plug is an important engine
component, which should be chec-
ked periodically, preferably by a
Yamaha dealer. Since heat and depo-
sits will cause any spark plug to
slowly erode, it 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.
The porcelain insulator around the
center electrode of the spark plug
should be a medium-to-light tan (the
ideal color when the vehicle is riddennormally). If the spark plug shows a
distinctly different color, the engine
could be operating improperly. Do not
attempt to diagnose such problems
yourself. Instead, have a Yamaha
dealer check the vehicle.
If the spark plug shows signs of elec-
trode erosion and excessive carbon
or other deposits, it should be repla-
ced.
Before installing a spark plug, the
spark plug gap should be measured
with a wire thickness gauge and, if
necessary, adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
Spark plug gap:
0.6-0.7 mm (0.024-0.028 in)
Specified spark plug:
BR8HS/NGK (for CS50 CS50Z)
BPR4HS/NGK (for CS50M)
1
ZAUM0037
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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.
EAU20061
Final transmission oil
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 up the
final transmission oil by riding the
scooter for several minutes, and
then stop the engine.
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.
1. Final transmission oil filler cap
2. Final transmission oil drain bolt
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 transmission
oil, and then install and tighten
the oil filler cap.
Tightening torque:
Final transmission oil drain bolt:
18 Nm (1.8 m•kgf, 13.0 ft•lbf)
Tightening torque:
Spark plug:
20 Nm (2.0 m•kgf, 14.5 ft•lbf)
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EWA11310
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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.
EAUM2101
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.
2. Check the coolant level through
the check window.
NOTE:
The coolant should be between the
minimum and maximum level marks.
1. Coolant level window
2. Maximum level mark
3. Minimum level mark
3. If the coolant is at or below the
minimum level mark, remove the
cowling A. (See page 6-5.)
4. Open the reservoir cap, and then
add coolant to the maximum
level mark.
Coolant reservoir capacity:
0.25 L (0.26 US qt) (0.22 Imp.qt)
Recommended final transmission
oil:
See page 8-1.
Oil quantity:
0.11 L (0.12 US qt) (0.10 Imp.qt)
PERIODIC MAINTENANCE AND MINOR REPAIR
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1. Coolant reservoir cap
2. Maximum level mark
3. Minimum level mark
ECA10471
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 cooling system will
not be protected against frost
and corrosion.
●If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content ofthe coolant as soon as possi-
ble, otherwise the effective-
ness of the coolant will be
reduced.
EWA10380
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WARNING
Never attempt to remove the radia-
tor cap when the engine is hot.
5. Close the reservoir cap, and then
install the cowling.
EAU33030
Changing the coolantEWA10380
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WARNING
Never attempt to remove the radia-
tor cap when the engine is hot.
The coolant must be changed at the
intervals specified in the periodic
maintenance and lubrication chart.
Have a Yamaha dealer change the
coolant.
EAU40370
Air filter element
The air filter element must be cleaned
and replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart. Have a Yamaha dealer
clean and replace the air filter ele-
ment.
PERIODIC MAINTENANCE AND MINOR REPAIR
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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
1. Throttle cable free play
The throttle cable free play should
measure 2-5 mm (0.08-0.2 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, adjust it as follows.
NOTE:
The engine idling speed must be
correctly adjusted before checking
and adjusting the throttle cable free
play.
1. Loosen the locknut.
1. Locknut
2. Adjusting nut
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.
1
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