Yamaha CW50, CW50L, CW50N Manual

OWNER’S MANUAL

CW50 / CW50L / CW50N

2B6-F8199-E0

INTRODUCTION

EAU10110

Welcome to the Yamaha world of motorcycling!

As the owner of the CW50/CW50L/CW50N, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your CW50/CW50L/CW50N. The owner’s manual does not only instruct you in how to operate, inspect and maintain your scooter, but also in how to safeguard yourself and others from trouble and injury.

In addition, the many tips given in this manual will help keep your scooter in the best possible condition. If you have any further questions, do not hesitate to contact your Yamaha dealer.

The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!

IMPORTANT MANUAL INFORMATION

EAU10150

Particularly important information is distinguished in this manual by the following notations:

				The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
				INVOLVED!
				Failure to follow WARNING instructions could result in severe injury or death to the
	WARNING
				scooter operator, a bystander, or a person inspecting or repairing the scooter.
				A CAUTION indicates special precautions that must be taken to avoid damage to
	CAUTION:
				the scooter.

NOTE:	A NOTE provides key information to make procedures easier or clearer.

NOTE:

●This manual should be considered a permanent part of this scooter and should remain with it even if the scooter is subsequently sold.

●Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your scooter and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.

EWA10030

WARNING

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS SCOOTER.

IMPORTANT MANUAL INFORMATION

EAUM1010

CW50/CW50L/CW50N

OWNER’S MANUAL ©2004 by MBK INDUSTRIE 1st edition, February 2004 All rights reserved

Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE

is expressly prohibited. Printed in France.

TABLE OF CONTENTS

SAFETY INFORMATION ..................	1-1
Further safe-riding points ................	1-4
DESCRIPTION ..................................	2-1
Left view ..........................................	2-1
Right view ........................................	2-2
INSTRUMENT AND CONTROL
FUNCTIONS .......................................	3-1
Main switch/steering lock ................	3-1
Indicator and warning lights ............	3-2
Speedometer unit
(CW50/CW50L)............................	3-3
Speedometer unit (CW50N) ............	3-4
Fuel gauge (CW50/CW50L) ............	3-4
Handlebar switches ........................	3-5
Front brake lever ............................	3-5
Rear brake lever .............................	3-6
Fuel and 2-stroke engine oil
tank caps .....................................	3-6
Fuel .................................................	3-7
Catalytic converter ..........................	3-7
2-stroke engine oil ..........................	3-8
Kickstarter .......................................	3-8
Securing bracket .............................	3-8
Seat ................................................	3-9
Anti-theft device housing ................	3-9
Luggage hook ...............................	3-10
Adjusting the shock
absorber assembly
(CW50L model only) ..................	3-10

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 ......................................	5-2
Acceleration and deceleration ........	5-2
Braking ...........................................	5-3
Tips for reducing fuel
consumption ...............................	5-3
Engine break-in ..............................	5-4
Parking ...........................................	5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR .................................	6-1
Periodic maintenance and
lubrication chart ..........................	6-2
Removing and installing the
cowling and panels .....................	6-5
Checking the spark plug .................	6-6
Final transmission oil ......................	6-7
Cleaning the air filter element ........	6-8
Adjusting the carburetor .................	6-9
Adjusting the throttle cable
free play ......................................	6-9
Tires .............................................	6-10
Cast wheels ..................................	6-12
Adjusting the front brake lever
free play ....................................	6-12

Adjusting the rear brake lever
free play ....................................	6-12
Checking the front brake pads
and rear brake shoes ...............	6-13
Checking the brake fluid level ......	6-14
Changing the brake fluid ..............	6-15
Checking and lubricating the
cables .......................................	6-15
Checking and lubricating the
throttle grip and cable ...............	6-15
Lubricating the front and rear
brake levers ..............................	6-16
Checking and lubricating the
centerstand...............................	6-16
Checking the front fork .................	6-16
Checking the steering ..................	6-17
Checking the wheel bearings .......	6-18
Battery .........................................	6-18
Replacing the fuse .......................	6-20
Replacing a headlight bulb ..........	6-20
Replacing the tail/brake light
bulb ...........................................	6-21
Replacing a turn signal light
bulb ...........................................	6-22
Troubleshooting ...........................	6-22
Troubleshooting chart ..................	6-23
SCOOTER CARE AND STORAGE...	7-1
Care ...............................................	7-1
Storage ..........................................	7-3

TABLE OF CONTENTS

SPECIFICATIONS .............................	8-1
CONSUMER INFORMATION.............	9-1
Identification numbers ....................	9-1

SAFETY INFORMATION

EAU10260

SCOOTERS ARE SINGLE TRACK

1VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS SCOOTER.

HE OR SHE SHOULD:

●OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF SCOOTER OPERATION.

●OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.

●OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.

●OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.

Safe riding

●Always make pre-operation checks. Careful checks may help prevent an accident.

●This scooter is designed to carry the operator and passenger.

●The failure of motorists to detect and recognize scooters in traffic is the predominating cause of automobile/scooter accidents. Many accidents have been caused by an automobile driver who did not see the scooter. Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident.

Therefore:

•Wear a brightly colored jacket.

•Use extra caution when approaching and passing through intersections, since intersections are the most likely places for scooter accidents to occur.

•Ride where other motorists can see you. Avoid riding in another motorist’s blind spot.

●Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current driver’s license.

•Make sure that you are qualified and that you only lend your scooter to other qualified operators.

•Know your skills and limits. Staying within your limits may help you to avoid an accident.

•We recommend that you practice riding your scooter where there is no traffic until you have become thoroughly familiar with the scooter and all of its controls.

●Many accidents have been caused by error of the scooter operator. A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed).

•Always obey the speed limit and never travel faster than warranted by road and traffic conditions.

1-1

SAFETY INFORMATION

•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 footrests.

•Never carry a passenger unless he or she can firmly place both feet on the passenger footrests.

●Never ride under the influence of alcohol or other drugs.

●This scooter is designed for onroad use only. It is not suitable for off-road use.

Protective apparel

The majority of fatalities from scooter accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries.

●Always wear an approved helmet.

●Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard.

●The use of a jacket, substantial shoes, trousers, gloves, etc., is effective in preventing or reducing 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 1 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, passenger, accessories and cargo must not exceed the maximum load limit of 185 kg (408 lb). When loading within this weight limit, keep the following in mind:

1-2

SAFETY INFORMATION

●Cargo and accessory weight should be kept as low and close to the scooter as possible. Make sure

1to distribute the weight as evenly as possible on both sides of the scooter to minimize imbalance or instability.

●Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely 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 responsible for the proper selection, installation 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 “Loading” when mounting accessories.

●Never install accessories or carry cargo that would impair the performance of your scooter. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or reflectors.

•Accessories fitted to the handlebar or the front fork area can create instability due to improper 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 aerodynamic effects. Wind may attempt to lift the scooter, or the scooter may become unstable in cross winds. These accessories may

also cause instability when passing or being passed by large vehicles.

•Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability, therefore, such accessories are not recommended.

●Use caution when adding electrical 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 FLAMMABLE:

•Always turn the engine off when refueling.

•Take care not to spill any gasoline on the engine or exhaust system when refueling.

•Never refuel while smoking or in the vicinity of an open flame.

1-3

SAFETY INFORMATION

●Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your scooter in an area that has adequate 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 system 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 kerosene heater, or near an open flame), otherwise it could catch fire.

●If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your

eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clothes.

EAU10370
Further safe-riding points
● Be sure to signal clearly when
making turns.	1

●Braking can be extremely difficult on a wet road. Avoid hard braking, 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 construction sites, and manhole covers become extremely slippery when wet. Slow down and cross them with caution. Keep the scooter upright, otherwise it could slide out from under you.

●The brake pads could get wet when you wash the scooter. After washing the scooter, check the brakes before riding.

1-4

SAFETY INFORMATION

●Always wear a helmet, gloves, trousers (tapered around the cuff and ankle so they do not flap), and

1a bright colored jacket.

●Do not carry too much luggage on the scooter. An overloaded scooter is unstable.

1-5

DESCRIPTION

EAU10410

Left view

	1	2	3	4 5	6
CW50N
1	2 3				CW50L	2
						10

1.Rear brake lever (page 3-6)

2.Speedometer unit (page 3-3)

3.Left handlebar switches (page 3-5)

4.Kickstarter (page 3-8)

5.Air filter element (page 6-8)

6.Final transmission oil filler cap (page 6-7)

7.Final transmission oil drain bolt (page 6-7)

8.Centerstand (page 6-16)

9.Battery/Fuse (page 6-18/6-20)

9 8 7

10.Shock absorber assembly spring preload adjusting ring (CW50L model only) (page 3-10)

2-1

DESCRIPTION

EAU10420

Right view

1

2

3

4

5

6

CW50N

4

5

6

2

9

8

7

1.Grab bar (page 5-2)

2.Oil tank cap (page 3-6)

3.Fuel tank cap (page 3-6)

4.Throttle grip (page 6-9)

5.Right handlebar switch (page 3-5)

6.Front brake lever (page 3-5)

7.Luggage hook (page 3-10)

8.Anti-theft device housing (page 3-9)

9.Securing bracket (page 3-8)

2-2

EAU10460

Main switch/steering lock

OPEN

PUSH

ZAUM0253

The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below.

EAU10640

ON “ ”

All electrical circuits are supplied with power, and the engine can be started. The key cannot be removed.

NOTE:

The headlight, meter lighting and taillight come on automatically when the engine is started.

INSTRUMENT AND CONTROL FUNCTIONS

EAU10660

OFF “”

All electrical systems are off. The key can be removed.

EAU10670

CHECK “”

The 2-stroke engine oil level warning light should come on. (See page 3-2.)

EAU10680

LOCK “ ”

The steering is locked, and all electrical systems are off. The key can be removed.

To lock the steering

1.Turn the handlebars all the way to the left.

2.Push the key in from the “” position, and then turn it to “” while still pushing it.

3.Remove the key.

To unlock the steering

Push the key in, and then turn it to “” while still pushing it.

	EWA10060
WARNING
Never turn the key to “ ” or “ ”
while the vehicle is moving, other-
wise the electrical systems will be
switched off, which may result in
loss of control or an accident. Make
sure that the vehicle is stopped be-
				3
fore turning the key to “ ” or “ ”.

3-1

INSTRUMENT AND CONTROL FUNCTIONS

EAU11001

Indicator and warning lights

CW50/CW50L

1 2

3

ZAUM0554

4

3

1.Left turn signal indicator light “”

2.Right turn signal indicator light “”

3.High beam indicator light “ ”

4.Oil level warning light “ ”

CW50N

1	2	3		4

ZAUM0522

1.Fuel level warning light “”

2.High beam indicator light “ ”

3.Oil level warning light “ ”

4.Turn signal indicator light “”

EAU11030

Turn signal indicator lights “” and “” (CW50/CW50L)

The corresponding indicator light flashes when the turn signal switch is pushed to the left or right.

EAU11020

Turn signal indicator light “” (CW50N)

This indicator light flashes when the turn signal switch is pushed to the left or right.

EAU11080

High beam indicator light “”

This indicator light comes on when the high beam of the headlight is switched on.

EAU11180

Oil level warning light “”

This warning light comes on when the key is in the “” position or when the oil level in the 2-stroke engine oil tank is low during operation. If the warning light comes on during operation, stop immediately and fill the oil tank with Yamalube 2 or equivalent 2-stroke engine oil of either JASO grade “FC” or ISO grades “EG-C” or “EG-D”. The warning light should go off after the 2-stroke engine oil tank has been refilled.

NOTE:

If the warning light does not come on when the key is in the “” position or does not go off after the 2-stroke engine oil tank has been refilled, have a Yamaha dealer check the electrical circuit.

3-2

INSTRUMENT AND CONTROL FUNCTIONS

ECA10010

CAUTION:

Do not operate the vehicle until you know that the engine oil level is sufficient.

EAUM1570

Fuel level warning light “” (CW50N)

●The electrical circuit of the warning light can be checked as follows.

Turn the key to “ ”. If the warning light does not come on, have a Yamaha dealer check the electrical circuit.

EAU11620

Speedometer unit (CW50/CW50L)

1 2

3

ZAUM0524

This warning light comes on and the last two segments of the fuel meter will start to flash when the fuel level drops below approximately 0.6 L (0.17 US gal) (0.14 Imp.gal). When this occurs, refuel as soon as possible.

NOTE:

ZAUM0555

1.Speedometer

2.Odometer

UK only

1 2

ZAUM0590

1.Speedometer

2.Odometer

●Do not allow the fuel tank to empty itself completely.

3-3

INSTRUMENT AND CONTROL FUNCTIONS

The speedometer unit is equipped with a speedometer and an odometer. The speedometer shows riding speed. The odometer shows the total distance traveled.

		EAUM1590	EAU12110
Speedometer unit (CW50N)			Fuel gauge (CW50/CW50L)
1	2	3
			1

3

ZAUM0523

ZAUM0556

1.Speedometer

2.Odometer

3.Fuel meter

The speedometer unit is equipped with a speedometer, an odometer and a fuel meter. The speedometer shows riding speed. The odometer shows the total distance traveled. The fuel meter indicates the amount of fuel in the fuel tank. (see page 3-2 for an explanation of the fuel level warning light.)

1. Fuel gauge

The fuel gauge indicates the amount of fuel in the fuel tank. The needle moves towards “E” (Empty) as the fuel level decreases. When the needle reaches “E”, approximately 1.2 L (0.32 US gal) (0.26 Imp.gal) of fuel remain in the fuel tank. If this occurs, refuel as soon as possible.

NOTE:

Do not allow the fuel tank to empty itself completely.

3-4

INSTRUMENT AND CONTROL FUNCTIONS

Handlebar switches

Left

1 2 3

ZAUM0557

1.Horn switch “ ”

2.Turn signal switch “/ ”

3.Dimmer switch “ / ”

Right

ZAUM0473 1

1. Start switch “”

EAU12342

EAU12400

Dimmer switch “/”

Set this switch to “” for the high beam and to “” for the low beam.

EAU12460

Turn signal switch “/”

To signal a right-hand turn, push this switch to “”. To signal a left-hand turn, push this switch to “”. When released, the switch returns to the center position. To cancel the turn signal lights, push the switch in after it has returned to the center position.

EAU12500

Horn switch “ ”

Press this switch to sound the horn.

EAUM1130

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 instructions prior to starting the engine.

EAU12900

Front brake lever

1

3

ZAUM0084

1. 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.

3-5

INSTRUMENT AND CONTROL FUNCTIONS

EAU12950

Rear brake lever

1

3

ZAUM0085

1. Rear brake lever

The rear brake lever is located on the left handlebar grip. To apply the rear brake, pull this lever toward the handlebar grip.

EAU13200

Fuel and 2-stroke engine oil tank caps

The fuel tank cap and the 2-stroke engine oil tank cap are located under the seat. (See page 3-9.)

Fuel tank cap

1 2

To install the 2-stroke engine oil tank cap, push it into the oil tank opening.

EWA10140

WARNING

Make sure that the fuel and 2-stroke engine oil tank caps are properly installed before riding the scooter.

ZAUM0560

1.Fuel tank cap

2.Oil 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.

2-stroke engine oil tank cap

To remove the 2-stroke engine oil tank cap, pull it off.

3-6

INSTRUMENT AND CONTROL FUNCTIONS

EAU13210

Fuel

1

2

ZAUM0020

1.Fuel tank filler tube

2.Fuel level

Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.

EWA10880

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 surfaces or plastic parts.

EAU13270

Recommended fuel:

REGULAR UNLEADED GASOLINE ONLY

Fuel tank capacity:

5.3 L (1.40 US gal) (1.17 Imp.gal)

Fuel reserve amount:

CW50 1.2 L (0.32 US gal) (0.26 Imp.gal)

CW50L 1.2 L (0.32 US gal) (0.26 Imp.gal)

CW50N 0.6 L (0.17 US gal) (0.14 Imp.gal)

Your Yamaha engine has been designed 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.

EAU13440

Catalytic converter

This vehicle is equipped with a catalytic converter in the muffler.

EWA10860

WARNING

The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before do- 3 ing any maintenance work.

ECA10700

CAUTION:

The following precautions must be observed to prevent a fire hazard or other damages.

●Use only unleaded gasoline. The use of leaded gasoline will cause unrepairable damage to the catalytic converter.

●Never park the vehicle near possible fire hazards such as grass or other materials that easily burn.

●Do not allow the engine to idle too long.

3-7