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Yamaha CW50N 1999-2002 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: CW50N Model Nickname: Jog Vehicle Type: Scooter Generation Generation Code: 1st Generation (Approx. 1999-2002) Codes Chassis Code Primary: CW50N Engine Code Primary: 5BM...
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Yamaha CW50N 1999-2002 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
CW50N
Model Nickname:
Jog
Vehicle Type:
Scooter
Generation
Generation Code:
1st Generation (Approx. 1999-2002)
Codes
Chassis Code Primary:
CW50N
Engine Code Primary:
5BM
👋 Introduction
Market Position
Segment:
Lightweight 50cc Scooter segment, popular for urban commuting and light recreational use.
Competitive Analysis
Competitors:
Honda Dio, Suzuki Address, Aprilia SR50, Peugeot Speedfight (depending on market).
Key Features
Vehicle Focus:
Compact size, agile handling, fuel efficiency, ease of operation, and Yamaha's reputation for reliability.
Manual Value Proposition
Benefit:
Cost-effective solution for maintaining optimal performance and longevity of the Yamaha CW50N.
📋 Manual Details
Coverage Areas
Covered Years:
1999, 2000, 2001, 2002
Page Count
Estimated Page Count:
300+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete disassembly, assembly, inspection, and repair of the 49cc 2-stroke engine.
Fuel System:
Carburetor inspection, cleaning, adjustment, and troubleshooting; fuel pump operation; fuel tank maintenance.
Ignition System:
CDI ignition system diagnostics, spark plug specifications, stator coil and pulse generator inspection.
Transmission:
Automatic CVT (Continuously Variable Transmission) inspection, belt replacement, clutch and torque converter servicing.
Cooling System:
Air cooling system components and maintenance.
Exhaust System:
Muffler and exhaust pipe inspection and replacement.
Chassis Frame:
Frame inspection, component mounting, and general chassis integrity checks.
Suspension Front:
Telescopic front fork inspection, maintenance, and seal replacement.
Suspension Rear:
Rear shock absorber inspection and replacement.
Brakes Front:
Drum brake adjustment, inspection, and component replacement.
Brakes Rear:
Drum brake adjustment, inspection, and component replacement.
Wheels Tires:
Wheel bearing inspection, tire pressure specifications, and tire replacement.
Electrical System:
Wiring diagrams, battery maintenance, lighting system (headlight, taillight, indicators), horn, and starter system.
Bodywork Cosmetics:
Panel removal and installation, seat, fairings, and storage compartment.
Procedures Included
Maintenance:
Routine checks, lubrication, filter replacement, spark plug replacement, brake adjustment, fluid level checks.
Troubleshooting:
Diagnostic charts for common starting problems, poor performance, electrical issues, and braking concerns.
Repair:
Detailed step-by-step instructions for engine rebuilds, carburetor overhauls, transmission servicing, electrical component replacement, and suspension work.
Disassembly Assembly:
Comprehensive guides for complete vehicle disassembly and reassembly.
Torque Specifications:
Essential torque values for critical fasteners across all systems.
Wiring Diagrams:
Detailed electrical schematics for accurate fault finding and repair.
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance to full engine and transmission overhauls, including diagnostics and troubleshooting.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Typically text-searchable PDF for easy navigation.
Print Quality
Quality:
High-resolution scans suitable for printing.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-stroke, single-cylinder, liquid-cooled (some variants may be air-cooled, manual will specify)
Displacement:
49.2 cc
Bore X Stroke:
39.0 mm x 41.4 mm
Compression Ratio:
7.4 : 1 (approximate, refer to manual for exact)
Carburetor Model:
Likely a Mikuni VM12 or similar.
Performance
Horsepower:
Approximately 6.5 - 7.0 HP (subject to market regulations and tuning)
Torque:
Approximately 5.5 - 6.0 Nm
Fuel System
Fuel Type:
Unleaded gasoline (min 91 RON)
Fuel Mixture:
Automatic oil injection (premix is not standard)
Fuel Tank Capacity:
Approx. 5.0 Liters
🔧 Transmission
Standard
Type:
Automatic CVT with V-belt drive
Optional
Options:
N/A
Features
Clutch:
Centrifugal automatic clutch
Gear Ratios:
Continuously variable, specific ratios managed by variator and clutch engagement.
Transmission Fluid:
No specific transmission fluid for the CVT; belt and roller wear are key maintenance points.
📐 Dimensions
Exterior
Overall Length:
Approx. 1730 mm
Overall Width:
Approx. 675 mm
Overall Height:
Approx. 1045 mm
Wheelbase:
Approx. 1275 mm
Weights
Dry Weight:
Approx. 85 kg
Curb Weight:
Approx. 90 kg (with fluids)
Cargo
Underseat Storage:
Yes, typically accommodates a helmet.
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Scooters are generally not subjected to automotive-style crash testing).
Active Features
Braking:
Front and rear drum brakes for reliable stopping power.
Lighting:
Headlight, taillight, brake light, and turn signals for visibility.
Passive Features
Frame Construction:
Steel frame providing structural integrity.
Ride Stability:
Designed for stable, predictable handling in urban environments.
💡 Technology Features
Infotainment
Features:
Basic instrument cluster with speedometer, odometer, fuel gauge (if equipped), and indicator lights. No advanced infotainment systems.
Driver Assistance
Features:
N/A (No driver-assistance features typical for this era and scooter type).
Connectivity
Features:
N/A (No Bluetooth or mobile connectivity).
🔧 Maintenance
Service Intervals
Oil Change Engine:
Refer to manual; typically every 3,000-5,000 km for 4-stroke, but 2-strokes rely on oil injection system. Check oil reservoir regularly.
Spark Plug Replacement:
Every 5,000 - 10,000 km, depending on plug type and usage. Manual specifies correct type and gap.
Cvt Belt Inspection:
Every 5,000 km; replacement typically between 10,000 - 20,000 km depending on wear.
Air Filter Cleaning Replacement:
Clean every 5,000 km, replace as needed or every 10,000-15,000 km.
Brake Adjustment:
Check and adjust as needed, typically every 5,000 km.
Fluid Specifications
Engine Oil Type:
2-stroke specific, high-quality oil injection type (e.g., Yamalube 2M or equivalent).
Coolant Type:
If liquid-cooled: Ethylene glycol-based antifreeze coolant. Manual specifies type and mixture ratio.
Gear Oil:
Refer to manual for transmission/final drive oil type and capacity (if applicable, some scooters do not have a separate gear oil for the CVT).
Known Issues
Common Problems:
Carburetor gumming due to stale fuel, CVT belt wear, weak starter motor, potential electrical connector corrosion.
Preventative Maintenance Tips:
Regular fuel stabilizer use if storing, checking oil levels frequently, cleaning air filter, ensuring proper electrical connections.
📚 Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Corporation, a globally recognized leader in motorcycles, musical instruments, and other motorized products.
Model Evolution
Lineage:
Part of the long-standing and popular Yamaha Jog scooter family, known for its sporty character and reliable performance.
Production
Manufacturing Location:
Primarily manufactured in Japan and other Yamaha global facilities.
Key Production Years:
1999-2002 (for this specific CW50N variant).
🏆 Awards & Recognition
Recognitions
Industry Awards:
N/A (Scooters are rarely recognized with formal industry awards like cars).
Ratings
Reliability Perception:
Generally perceived as a reliable and durable scooter within its class, consistent with Yamaha's reputation.
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