PW50 (5PG8) EUROPE,SOUTH AFRICA,JAPAN

Transcription

1 PW50 (5PG8) OPE,SOUTH AFRICA,JAPAN 1C5PG-300E1 ( 2C5PG-300E1 ) A2

2 PW50 PARTS CATALOGUE 2003 by Yamaha Motor Co., Ltd. 1st edition, May 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan. A3

3 PW50 A4

4 FOREWORD This Parts Catalogue is related to the parts for the model(s) on the cover page. When you are ordering replacement parts, please refer to this Parts Catalogue and quote both part numbers and part names correctly. 6. The asterisk (*) before a reference number indicates modified items after the first edition. 1. Modifications or additions which have been made after the issue of the Parts Catalogue will be announced in the Parts News. It is advisable that you make the necessary corrections to the Parts Catalogue according to the Parts News. 2. Abbreviations The following abbreviations are used in this Parts Catalogue. UR Use specified parts number. UN Use as many as needed. AP Alternate Parts LM Locally Made (Parts need to be ordered locally) F# Frame No. (Applicable machine No.) O/S Over Size 3. The number of components for assembly Parts, which are to be supplied in an assembly, are listed with a dot (.) in front of the part name as shown below. The numeral appearing to the right of each component part indicates the quantity of parts for each assembly unit. PART DESCRIPTION Q TY 2F FRONT FLASHER LIGHT ASSY BULB (6V 18W) 1 4. Applicable colours of graphics are represented in the as shown below. PART DESCRIPTION Q TY 2N X5 FUEL TANK COMP. 2 MXR 3J GRAPHIC, FUEL TANK 1 FOR MXR 5. Note that the illustrations for reference in finding parts numbers are not to be used for assembling. When assembling, please use the applicable service manual. A5

5 FOREWORD 7. Applicable Serial No. Engine Serial No. Frame Serial No. 8. Applicable Colour Code (The (*) mark shows Model colour.) Abbreviation Colour Name Colour Code DPBSE(*) DEEP PURPLISH BLUE SOLID E 0583 LGB LOW GLOSS BLACK 0098 RW RADICAL WHITE 00UJ SL SILVER 0035 YB YAMAHA BLACK 0033 A6

6 MODEL LABEL (1) A label called Model Label is affixed in the location as indicated in (3) below. When using this parts catalogue, please be sure to cross reference the model code production code No. in the catalogue with the model code production code No. indicated on the Model Label affixed onto the product concerned. (2) Model Label Indication (3) Model Label Affixing Location (4) Colouring Information (5) Model Code Production Code Number of Model Listed in This Parts Catalogue Model Code 5PG8 Production Code No. Country (destination) 010 AUSTRIA 020 BELGIUM NETHELANDS 030 SWITZERLAND DENMARK 040 FINLAND IRELAND NORWAY 050 SPAIN 070 UNITED KINGDOM 080 GREECE 090 JAPAN 100 PORTUGAL 110 SWEDEN 120 SOUTH AFRICA Model Code Production Code No. Country (destination) Model Code Colouring Type Code Colour Code Colour Name Abbreviation 5PG8 A 0583 DEEP PURPLISH BLUE SOLID E DPBSE A7

7 CONTENTS ENGINE CYLINDER... B2 CRANKSHAFT & PISTON... B3 OIL PUMP... B4 INTAKE... B5 CARBURETOR... B6 EXHAUST... B7 CRANKCASE... B8 STARTER... B9 CLUTCH... B10 TRANSMISSION... B11 CHASSIS FRAME... B12 FRONT FENDER... B13 SIDE COVER... B14 OIL TANK... B15 REAR ARM & SUSPENSION... C2 DRIVE SHAFT... C3 FRONT FORK... C4 FUEL TANK... C5 SEAT... C6 FRONT WHEEL... C7 REAR WHEEL... C8 STEERING HANDLE & CABLE... C9 STAND & FOOTREST... C10 GENERATOR... C11 HANDLE SWITCH & LEVER... C12 ELECTRICAL 1... C13 INDEX NUMERICAL INDEX... M1

8 FIG. 1 CYLINDER PART DESCRIPTION 1 4J HEAD, CYLINDER GASKET, CYLINDER HEAD PLUG, SPARK (NGK BPR4HS) PLUG, SPARK (NGK BPR4HS) 1 4 4J CYLINDER PT GASKET, CYLINDER BOLT, STUD NUT, FLANGE B2

9 FIG. 2 CRANKSHAFT & PISTON PART DESCRIPTION 1 3L CRANKSHAFT ASSY L CRANK L CRANK U PIN, CRANK E ROD, CONNECTING N7.BEARING KEY, WOODRUFF WASHER WASHER, SPRING NUT BEARING OIL SEAL OIL SEAL U A0 PISTON (STD) U PISTON (0.25MM O/S) AP 18U PISTON (0.50MM O/S) AP 15 3L PIN, PISTON PISTON RING SET (STD) PISTON RING SET (0.25MM O/S) AP PISTON RING SET (0.50MM O/S) AP CIRCLIP BEARING B3

10 FIG. 3 OIL PUMP PART DESCRIPTION 1 3L OIL PUMP ASSY OIL SEAL O-RING GASKET SCREW PLATE, ADJUSTING NUT BOLT, UNION L GEAR, WORM WHEEL (56T) PIN, SPRING CIRCLIP L PIPE, DELIVERY CLIP SCREW, PAN HEAD SCREW, PAN HEAD L COVER, OIL PUMP L COVER, OIL PUMP SCREW, TAPPING B4

11 FIG. 4 INTAKE PART DESCRIPTION 1 3L REED VALVE ASSY L REED, VALVE L STOPPER, REED VALVE SCREW, PAN HEAD WASHER, SPRING L PLATE,REED VALVE HK GASKET, VALVE SEAT L GASKET, VALVE SEAT L MANIFOLD, INTAKE SCREW, PAN HEAD X CASE, AIR CLEANER X CAP, CLEANER CASE X ELEMENT, AIR CLEANER SCREW, PAN HEAD WASHER, PLATE X JOINT, AIR CLEANER CLIP X STAY SCREW, WITH WASHER B5

12 FIG. 5 CARBURETOR PART DESCRIPTION 1 5PG CARBURETOR ASSY L GASKET, FLOAT CHAMBER JET, MAIN (# 70) L NOZZLE, MAIN L JET, PILOT (# 40) SCREW, PAN HEAD WASHER, SPRING L GASKET L CABLE ADJUST SCREW SET R CAP L FLOAT L NEEDLE VALVE ASSY PIN, FLOAT L VALVE, THROTTLE R 1490J 00.NEEDLE SET SPRING, THROTTLE VALVE R THROTTLE SCREW SET PLUNGER, STARTER SPRING, PLUNGER SCREW, OVAL HEAD R AIR SCREW SET NUT SCREW, PAN HEAD PIPE M SEAL V INSULATOR B6

13 FIG. 6 EXHAUST PART DESCRIPTION 1 4X EXHAUST PIPE ASSY X GASKET, EXHAUST PIPE SCREW BOLT WASHER, SPRING WASHER, PLATE X PROTECTOR ASSY SCREW, PAN HEAD WASHER, PLATE RV WASHER, PROTECTOR X GASKET, MUFFLER CLIP X SILENCER ASSY SCREW, PAN HEAD WASHER, SPRING WASHER, PLATE BOLT WASHER, SPRING WASHER, PLATE B7

14 FIG. 7 CRANKCASE PART DESCRIPTION 1 4X CRANKCASE PIN, DOWEL SCREW, PAN HEAD J CRANKCASE L HOLDER SCREW, PAN HEAD E DAMPER, ENGINE MOUNT J COVER, GENERATOR SCREW, PAN HEAD X COVER, CRANKCASE L BUSH PIN, DOWEL L GASKET, CRANKCASE COVER SCREW, PAN HEAD SCREW, PAN HEAD BOLT, FLANGE GASKET J PLUG, OIL O-RING BOLT J PLATE SCREW, PAN HEAD WASHER, SPRING X PROTECTOR X CLAMP B8

15 FIG. 8 STARTER PART DESCRIPTION 1 3L KICK SHAFT ASSY L GUIDE, SPRING SPRING, TORSION J KICK CRANK ASSY T COVER, KICK LEVER BOLT L GEAR, KICK PINION (13T) L CLIP L GEAR, PUMP DRIVE OIL SEAL B9

16 FIG. 9 CLUTCH PART DESCRIPTION 1 3L GEAR, PRIMARY DRIVE (33T) L ABSORBER L ABSORBER L PLATE, THRUST L SPACER COLLAR KEY, STRAIGHT WASHER, CONICAL SPRING NUT CIRCLIP WASHER, PLATE L CLUTCH CARRIER ASSY L WASHER T DAMPER, CLUTCH WEIGHT L SPRING, CLUTCH WEIGHT L SHAFT, CLUTCH WEIGHT L CLUTCH HOUSING COMP CIRCLIP B10

17 FIG. 10 TRANSMISSION PART DESCRIPTION 1 3L MAIN AXLE COMP. (15T) L SHIM, PINION L PLATE, COVER L STOPPER BOLT L PINION, DRIVEN (19T) BEARING L SHIM, THRUST L COLLAR, DISTANCE SCREW OIL SEAL B11

18 FIG. 11 FRAME PART DESCRIPTION 1 36E FRAME COMP YB NUT, SELF-LOCKING BOLT, FLANGE B12

19 FIG. 12 FRONT FENDER PART DESCRIPTION 1 3PT FENDER, FRONT SCREW, WITH WASHER PT GRAPHIC E STAY, FENDER B13

20 FIG. 13 SIDE COVER PART DESCRIPTION 1 3PT COVER, SIDE SCREW, WITH WASHER BOLT, WITH WASHER X DAMPER, LOCATING PT 2173L 90 GRAPHIC SET PT COVER, SIDE PT COVER, SIDE SCREW, WITH WASHER X TOOL KIT B14

21 FIG. 14 OIL TANK PART DESCRIPTION 1 4X TANK, OIL Y OIL TANK CAP ASSY GROMMET X PIPE, OIL SPRING, COMPRESSION CLIP X4 2172K 00 BRACKET X GROMMET X GUARD, MUD B15

22 FIG. 15 REAR ARM & SUSPENSION PART DESCRIPTION 1 3L REAR ARM COMP LGB BOLT WASHER, SPRING X REAR ARM COMP J END BEARING OIL SEAL BOLT, FLANGE NUT, FLANGE WASHER, PLATE BUSH, REAR SHOCK ABSORBER PT SHOCK ABSORBER ASSY, REAR BOLT WASHER, SPRING A7 WASHER, PLATE A0 WASHER, PLATE BOLT, FLANGE C2

23 FIG. 16 DRIVE SHAFT PART DESCRIPTION 1 4J HOUSING, DRIVE SHAFT M GEAR, DRIVE PINION BEARING (B6201) L SHIM, DRIVE PINION BEARING (B6201) SCREW SPACER J RING GEAR COMP BEARING (B6202RS) SPACER L PLATE, COVER BOLT J COVER, HOUSING BOLT, FLANGE BUSH, REAR SHOCK ABSORBER BEARING (B6202) KOYO A9 O-RING L SHAFT DRIVE ASSY SPRING, COMPRESSION L RETAINER, SPRING CIRCLIP C3

24 FIG. 17 FRONT FORK PART DESCRIPTION 1 3PT FRONT FORK ASSY SL 2 3PT UNDER BRACKET COMP YJ RACE, BALL PT INNER TUBE COMP E SEAL, DUST CIRCLIP V METAL, SLIDE E COLLAR R SPRING, REBOUND X OUTER TUBE COMP. (L.H) SL 11 4X SPRING, FRONT FORK L RUBBER E SEAT, SPRING LOWER PT FRONT FORK ASSY (R.H) SL BOLT, FLANGE X CROWN, HANDLE BOLT, FLANGE WASHER H3 WASHER, PLATE E RACE, BALL E RACE, BALL PT RACE, BALL BALL X PLATE SCREW, WITH WASHER C4

25 FIG. 18 FUEL TANK PART DESCRIPTION 1 3PT FUEL TANK COMP FG CAP ASSY HOSE (L350) X FUEL COCK ASSY GROMMET WASHER, PLATE F4 COLLAR BOLT NUT, FLANGE PG 2467E 00 CAP R DAMPER, LOCATING V BAND, TANK FITTING E PIPE, FUEL CLIP HOSE (L130) CLIP SCREW, PAN HEAD WASHER, PLATE PT A0 GRAPHIC SET C5

26 FIG. 19 SEAT PART DESCRIPTION 1 3PT SINGLE SEAT ASSY PT COVER, SEAT C6

27 FIG. 20 FRONT WHEEL PART DESCRIPTION 1 5M UJ WHEEL COMP RW SPACER E FLANGE, SPACER OIL SEAL T PLATE, BRAKE SHOE LGB OIL SEAL PT W253A 10 BRAKE SHOE KIT E SPRING, RETURN PLUG, TAPER T LEVER, CAMSHAFT E CAMSHAFT BOLT NUT TIRE ( ) UR INOUE TIRE ( PR M29) UR BRIDGESTONE TUBE (2.50/ ) INOUE BEARING (B6200) NTN 17 2T RING N AXLE, WHEEL COLLAR NUT, SELF-LOCKING WASHER, PLAIN E 2539F 00 PLATE 1 3 C7

28 FIG. 21 REAR WHEEL PART DESCRIPTION 1 5M UJ REAR WHEEL COMP RW TIRE ( ) UR INOUE TIRE ( PR M29) UR BRIDGESTONE TUBE (2.50/ ) INOUE 4 2T RING PT W253A 10 BRAKE SHOE KIT E SPRING, RETURN L CAMSHAFT L LEVER, CAMSHAFT BOLT NUT, SELF-LOCKING E WASHER WASHER, PLATE X RING A5 COLLAR E 2539F 00 PLATE 1 3 C8

29 FIG. 22 STEERING HANDLE & CABLE PART DESCRIPTION 1 3PT HANDLEBAR NUT, U E WASHER X GRIP X TUBE, THROTTLE GUIDE X GRIP (RIGHT) CONNECTOR, CABLE X CABLE, THROTTLE PG CABLE, THROTTLE X CABLE, PUMP L CAP X CABLE, STARTER PT CABLE, BRAKE TB BAND, SWITCH CORD SPRING, COMPRESSION NUT PIN X CABLE, BRAKE SPRING, COMPRESSION NUT PIN R PROTECTOR, HANDLEBAR BAND, SWITCH CORD C9

30 FIG. 23 STAND & FOOTREST PART DESCRIPTION FOOTREST X COVER, FOOTREST PIN, CLEVIS PIN, COTTER SPRING, TORSION X STAND, MAIN YB 7 3L BRACKET, MAIN STAND SPRING, TENSION X STOPPER, MAIN STAND PIN, CLEVIS CLIP WASHER, PLATE BOLT WASHER, PLATE C10

31 FIG. 24 GENERATOR PART DESCRIPTION 1 3L M0 ROTOR ASSY PT BASE ASSY X M0.COIL, LIGHTING Y M0.COIL, CHARGE L M0.COIL, PULSER PT 8131X 00.CORD ASSY SCREW, PAN HEAD SCREW, PAN HEAD SCREW, PAN HEAD WASHER, SPRING SCREW, PAN HEAD WASHER, SPRING SCREW, FLAT HEAD C11

32 FIG. 25 HANDLE SWITCH & LEVER PART DESCRIPTION 1 2T LEVER SCREW NUT, U PT LEVER HOLDER ASSY (RIGHT) T LEVER SCREW SCREW, PAN HEAD NUT, U BAND, SWITCH CORD TB BAND, SWITCH CORD X STOPPER CLAMP C12

33 FIG. 26 ELECTRICAL 1 PART DESCRIPTION 1 3PT C.D.I. UNIT ASSY SCREW, PAN HEAD WASHER, SPRING WASHER, PLATE PT CONTROL UNIT ASSY J BAND JP IGNITION COIL ASSY SCREW, PAN HEAD PLUG CAP ASSY PT WIRE HARNESS ASSY K DIODE ASSY C13

34 NUMERICAL INDEX PART GRID PART GRID PART GRID PART GRID PART GRID PART GRID 4J B B 2 4J B 2 3PT B 2 3L B 3 3L B 3 3L B B B B 3 18U A0 B 3 3L B 3 18U B 3 18U B 3 2E B 3 54U B 3 3L B 4 3L B B 4 3L B 4 3L B 9 3L B 5 3L B 5 3L B 5 3L B 5 3HK B 5 3L B 5 3L B 5 5PG B 6 36R B 6 36R B 6 17L B 6 3L B B B 6 3L B 6 3L B 6 1R B B 6 3L B 6 3L B B 6 3L B B 6 3L B B 6 1V B 6 4X B 5 4X B 5 4X B 5 4X B 5 4X B 5 4X B 7 4X B 7 4X B 7 4X B 7 4X B 7 3RV B 7 36R 1490J 00 B 6 1M B 6 4X B 8 4J B 8 4J B 8 3L B 8 2E B 8 4J B 8 4J B 8 3L B 4 4X B 8 3L B 4 3L B 8 4X B 8 4X B 8 3L B 9 2T B 9 17J B 9 3L B 9 3L B 9 3L B 9 3L B 10 3L B 10 3L B 10 3L B 10 3L B 10 3L B 10 3L B 10 3L B 10 3L B 10 2T B 10 3L B 10 3L B 8 3L B 11 3L B 11 3L B 11 3L B 11 3L B 11 3L B 11 15L B 11 15L C 3 36E B 12 3PT B 13 36E B 13 4X C 4 3PT B 13 4X B 15 3PT B 14 4X4 2172K 00 B 15 3PT B 14 3PT 2173L 90 B 14 3PT B 14 4X B 15 4X B 15 1Y B 15 4X B 15 3L C 2 4X C 2 4J C 2 3PT C C 2 C 3 3PT C 4 3PT C 4 4X C 4 3PT C 4 2E C 4 54V C 4 4X C 4 2E C 4 2E C 4 36R C 4 3L C 4 3PT C 4 3PT C 4 2E C 4 2E C 4 3YJ C 4 4X C 4 3PT C 5 59V C 5 3R C 5 4X B 14 3PT A0 C 5 36E C 5 4X C 5 2FG C 5 5PG 2467E 00 C 5 3PT C 6 3PT C 6 2E C 7 2T C 7 2E C 7 C 8 2E C 7 2T C 7 5M UJ C 7 4N C 7 2T C 7 C 8 4X C 8 3L C 8 3L C 8 5M UJ C 8 36E 2539F 00 C 7 C 8 2E C 8 3PT C 9 36R C 9 2E C 9 4X C 9 4X C 9 4X C 9 4X C C 9 5L C 9 4X C 9 5PG C 9 4X C 9 4X C 9 3PT C 9 4X C 9 4X C 10 4X C 10 3L C 10 4X C C 10 4X B 14 4J C 3 3L C 3 59M C 3 3L C 3 4J C 3 4J C 3 3L C 3 4X M0 C 11 3PT 8131X 00 C 11 3K C 13 4JP C C 13 3PT C 13 3PT C 12 2T C 12 2T C 12 3TB C 9 C C C 9 4Y M0 C 11 3PT C 13 4J C 13 3L M0 C 11 3PT C 11 3L M0 C 11 3PT C 13 3PT W253A 10 C 7 C C C C B C C B B B B B C C B C B B B B B 13 B 14 C B B C C C C C A0 C C H3 C A7 C C B B B C C C B B C F4 C C A5 C B B B B C C C B 15 C C B B B C B C B C C C C C B C C C C 10 M1

35 NUMERICAL INDEX PART GRID PART GRID PART GRID PART GRID PART GRID PART GRID B C B C C B B 6 C B 7 B 8 C 2 C B 5 B 7 C 5 C B 7 C B 7 C B B B B B B C C B C B B A9 C C C C C C B B B N7 B B C B C C C C C 7 C C 7 C B B C C C B C C B B 2 C C C B C B C B C B B C C B B B C B B B C B C B B B B 5 B C C B C B B B 8 M2