🏷️ Basic Information

Make:

Yamaha

Model:

Zuma 50

Model Variant:

BWs 50 (International Market)

Product Type:

Digital Workshop Repair Manual

Chassis Code:

Likely 5S9 (for later models, but early models may vary)

Engine Code:

Likely A137E (or similar 49cc, 2-stroke)

👋 Introduction

Vehicle Segment:

Compact, lightweight, urban scooter popular for its distinctive styling and agility.

Target Audience:

Young riders, commuters, and those seeking an economical and fun mode of transportation.

Key Competitors:

Honda Metropolitan, Kymco Agility 50, Aprilia Scarabeo 50, Aprilia SR50.

Styling:

Unique, rugged, dual-headlight design with off-road inspired styling.

Performance Character:

Nimble handling, peppy acceleration for its class, suitable for city riding.

Durability:

Yamaha's reputation for reliable and durable 2-stroke engines.

📋 Manual Details

Applicable Years:

2001 onwards

Estimated Page Count:

300+

Manual Type:

Workshop Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, inspection, assembly, and tuning of the 49cc 2-stroke engine, including cylinder, piston, crankshaft, connecting rod, and all related components.

Fuel System:

Carburetor identification, adjustment, cleaning, and overhaul; fuel pump operation and maintenance; fuel line inspection and replacement.

Ignition System:

CDI unit testing, spark plug specifications and replacement, ignition coil diagnostics, and stator/rotor inspection.

Cooling System:

Forced air cooling system component inspection and fan operation.

Exhaust System:

Muffler and exhaust pipe inspection, cleaning, and replacement procedures.

Transmission:

Automatic centrifugal clutch and variator (V-belt drive) inspection, maintenance, and replacement; gearbox oil change and inspection.

Brakes:

Front and rear brake system service, including hydraulic disc brake overhaul (master cylinder, caliper, hose replacement), brake pad inspection and replacement, and brake fluid specifications and bleeding procedures.

Suspension:

Front telescopic fork inspection, oil level and seal replacement; rear monoshock absorber inspection and replacement.

Steering:

Handlebar and steering bearing inspection, adjustment, and replacement.

Electrical System:

Wiring diagrams, battery maintenance and testing, lighting system (headlight, taillight, indicators), horn, starter motor, and charging system (stator, regulator/rectifier) diagnostics.

Chassis And Bodywork:

Frame inspection, seat removal, body panel removal and installation, fender replacement, and general chassis component checks.

Routine Maintenance:

Oil changes, filter replacements (air, fuel), spark plug checks, brake adjustments, tire pressure checks, and general lubrication.

Troubleshooting Diagnostics:

Systematic diagnostic flowcharts and step-by-step troubleshooting for common and uncommon issues across all vehicle systems.

Engine Overhaul:

Detailed instructions for complete engine teardown, cleaning, inspection of wear limits, component replacement, and reassembly.

Transmission Repair:

Variator roller replacement, clutch shoe inspection and replacement, and gearbox disassembly/assembly.

Brake System Service:

Brake caliper piston service, bleeding, pad replacement, and fluid flushing.

Electrical Component Replacement:

Step-by-step guidance for replacing bulbs, fuses, starter solenoids, CDI units, and other electrical parts.

Suspension Fork Rebuild:

Front fork seal replacement and oil level adjustment.

Diagnostic Charts:

Comprehensive diagnostic flowcharts for identifying root causes of malfunctions.

Special Tools:

Identification and usage of specialized tools required for specific repair procedures.

Torque Specifications:

Precise torque values for all critical fasteners to ensure proper assembly and prevent component damage.

Clearances And Tolerances:

Specifications for engine component clearances (piston-to-cylinder, ring gap, etc.) and bearing tolerances.

Wiring Diagrams:

Detailed and clearly labeled electrical wiring diagrams for all circuits.

Illustrations And Diagrams:

High-quality illustrations, exploded views, and diagrams to aid in understanding assembly and disassembly procedures.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution, suitable for professional printing.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

Text Searchability:

Fully searchable text for quick information retrieval.

Internal Linking:

Hyperlinked table of contents and cross-references for efficient navigation.

⚙️ Engine Specifications

Engine Type:

49cc liquid-cooled, 2-stroke, reed valve, single-cylinder

Bore X Stroke:

39.0 mm x 41.4 mm

Compression Ratio:

7.4:1 (approximate)

Carburetion:

Mikuni VM15SC

Ignition:

CDI (Capacitor Discharge Ignition)

Horsepower:

Approx. 4.2 HP @ 7,000 RPM

Torque:

Approx. 3.1 lb-ft @ 6,000 RPM

Fuel Type:

Unleaded gasoline (minimum 87 octane recommended)

Oil Mixture:

Pre-mix or Autolube system (manual will detail specifics)

Fuel Tank Capacity:

4.0 L (1.06 US gal)

🔧 Transmission

Transmission Type:

Automatic V-belt (CVT - Continuously Variable Transmission)

Clutch Type:

Automatic centrifugal clutch

Gear Reduction:

Single stage reduction gear

📐 Dimensions

Length:

1,750 mm (68.9 in)

Width:

665 mm (26.2 in)

Height:

1,040 mm (40.9 in)

Wheelbase:

1,255 mm (49.4 in)

Dry Weight:

82 kg (181 lbs)

Gross Vehicle Weight Rating:

N/A (typically not specified for scooters in this class)

Front Tire:

120/90-10

Rear Tire:

130/90-10

Front Wheel Size:

10 inch

Rear Wheel Size:

10 inch

🛡️ Safety Features

Crash Test Ratings:

N/A (Scooters are typically not subjected to the same crash testing standards as automobiles.)

Braking System:

Front hydraulic disc brake, Rear drum brake (early models may have rear drum).

Lighting:

Dual Halogen Headlights, Taillight, Stoplight, Turn Signals.

💡 Technology Features

Dashboard:

Analog speedometer, fuel gauge, odometer, and indicator lights.

ABS:

N/A (ABS is not a standard feature on this model.)

Bluetooth:

N/A (Not equipped with Bluetooth or smartphone integration.)

🔧 Maintenance

Engine Oil Change:

Every 3,000 km (1,860 miles) or 6 months, whichever comes first (check manual for specific gearbox oil).

Air Filter Cleaning:

Every 1,000 km (620 miles), replace as needed.

Spark Plug Inspection:

Every 1,000 km (620 miles), replace as needed. Recommended: NGK CR7HSA or equivalent.

V Belt Inspection:

Every 3,000 km (1,860 miles), replace as needed.

Gearbox Oil Type:

Yamaha Genuine Gear Oil 10W-40 or API GL-4, SAE 80.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Coolant Type:

N/A (Air-cooled, but manual covers engine cleaning for optimal cooling airflow.)

Carburetor Clogging:

Common issue with 2-stroke engines, especially if fuel is left to sit. Requires regular cleaning and proper fuel storage.

Variator Wear:

Wear on variator rollers and clutch shoes can lead to reduced acceleration and top speed. Routine inspection and replacement are key.

2-Stroke Smoking:

Normal for 2-stroke engines, but excessive smoke can indicate incorrect oil mix, rich fuel mixture, or engine wear.

📚 Vehicle History

Manufacturer History:

Yamaha Motor Corporation is a Japanese manufacturer of motorcycles, marine products, and other motorized products. Known for innovation and performance across its product lines.

Original Release:

The Zuma (BWs in many markets) was first introduced in 1988, featuring a robust design and distinctive off-road styling.

2001 Update:

Models from 2001 onwards typically feature a 49cc liquid-cooled 2-stroke engine, revised bodywork, and improved features over earlier iterations.

Manufacturing Location:

Primarily manufactured in Japan and/or Taiwan for global markets.

🏆 Awards & Recognition

Industry Accolades:

While specific awards are not widely documented, the Zuma line is recognized for its distinctive style, fun factor, and urban commuting practicality.

Reliability Perception:

Generally high reliability associated with Yamaha products.