Yamaha CW50, CW50L, CW50N User 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

Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
EAU10150
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death 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 the scooter.
A NOTE provides key information to make procedures easier or clearer.
to the
NOTE:
This manual should be considered a permanent part of this scooter and should remain with it even if the scooter is sub-
sequently 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
OWNERS 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
SPECIFICATIONS .............................8-1
CONSUMER INFORMATION.............9-1
Identification numbers ....................9-1
TABLE OF CONTENTS

SAFETY INFORMATION

SCOOTERS ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND
1
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 INSTRUC-
TIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF SCOOTER OPERATION.
OBSERVE THE WARNINGS AND
MAINTENANCE REQUIRE­MENTS IN THE OWNER’S MAN- UAL.
OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING TECHNIQUES.
OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED BY THE OWNERS MANUAL AND/OR WHEN MADE NECES­SARY BY MECHANICAL CONDI­TIONS.
EAU10260
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 ap-
proaching 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 motorists blind spot.
Many accidents involve inexperi-
enced 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 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 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.
1-2
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, 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
SAFETY INFORMATION
Cargo and accessory weight
should be kept as low and close to the scooter as possible. Make sure
1
to distribute the weight as evenly as possible on both sides of the scooter to minimize imbalance or instability.
Shifting weights can create a sud-
den 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 “Load- ing 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
1-3
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 electri-
cal accessories. If electrical acces­sories exceed the capacity of the scooters 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 gaso­line on the engine or exhaust system when refueling.
Never refuel while smoking or in the vicinity of an open flame.
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 gaso-
line, 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.
1-4
EAU10370
Further safe-riding points
Be sure to signal clearly when
making turns.
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 cor-
ner 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
SAFETY INFORMATION
Always wear a helmet, gloves,
trousers (tapered around the cuff and ankle so they do not flap), and
1
a bright colored jacket.
Do not carry too much luggage on
the scooter. An overloaded scoot­er is unstable.
1-5
Left view

DESCRIPTION

EAU10410
CW50N
1 23
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)
1 23
2-1
45 6
CW50L
10
789
10.Shock absorber assembly spring preload adjusting ring (CW50L model only) (page 3-10)
2
DESCRIPTION
Right view
EAU10420
2
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
9
3 4 5 61
87
2-2
CW50N
4 56

INSTRUMENT AND CONTROL FUNCTIONS

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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.
OFF “”
EAU10660
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 “” posi- tion, 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, other­wise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the vehicle is stopped be­fore turning the key to “” or “”.
3
3-1
INSTRUMENT AND CONTROL FUNCTIONS
Indicator and warning lights
CW50/CW50L
12
3
ZAUM0554
1. Left turn signal indicator light “”
2. Right turn signal indicator light “”
3. High beam indicator light “”
4. Oil level warning light “”
EAU11001
CW50N
12 34
High beam indicator light “”
This indicator light comes on when the
EAU11080
high beam of the headlight is switched on.
Oil level warning light “”
EAU11180
This warning light comes on when the key is in the “” position or when the oil
ZAUM0522
1. Fuel level warning light “”
34
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.
Turn signal indicator light “”
EAU11020
(CW50N)
This indicator light flashes when the tu rn signal s witch is pu shed to the left or
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.
right.
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)
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:
Do not allow the fuel tank to empty
itself completely.
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)
12
3
ZAUM0555
1. Speedometer
2. Odometer
UK only
12
ZAUM0590
1. Speedometer
2. Odometer
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.
3
EAUM1590
Speedometer unit (CW50N)
12 3
ZAUM0523
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.)
EAU12110
Fuel gauge (CW50/CW50L)
1
ZAUM0556
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
ZAUM0557
1. Horn switch “”
2. Turn signal switch /
3. Dimmer switch /
Right
1
ZAUM0473
1. Start switch “”
1
EAU12342
Dimmer switch /
EAU12400
EAU12900
Front brake lever
Set this switch to “” for the high beam and to “” for the low beam.
EAU12460
1
Turn signal switch /
To signal a right-hand turn, push this switch to “”. To signal a left-hand turn, push this switch to “”. When re-
3
leased, the switch returns to the center
2
3
lights, push the switch in after it has re­turned to the center position.
position. To cancel the turn signal
Horn switch “”
EAU12500
Press this switch to sound the horn.
EAUM1130
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.
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.
3-5
INSTRUMENT AND CONTROL FUNCTIONS
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.
EAU12950
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
12
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.
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.
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, oth-
erwise it may overflow when the fuel warms up and expands.
Avoid spilling fuel on the hot en-
gine.
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.
3-7
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 do­ing 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 pos-
sible fire hazards such as grass or other materials that easily burn.
Do not allow the engine to idle
too long.
3
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