Yamaha SH50 Razz Service Manual 1987–2001 (P/N LIT-11616-05-80)

This Yamaha SH50 Razz factory service manual covers the SH50T (2EK) and SH50MT (2HU). Yamaha issued the U.S. SH50/M (T-A) Service Manual in January 1990 as the first edition, P/N LIT-11616-05-80. Use the model code and starting serial numbers above to match the manual to your scooter.

Search, Bookmarks, and Wiring Diagram Readability

Finding text and diagrams: OCR text search covers most of the manual, with some recognition errors and incomplete coverage of diagram labels. Bookmarks take you to all seven chapters, their subsections, and the full wiring diagram. The external index shortcut requires a separate file. Small wire-color codes and connector markings are best read at higher zoom, especially on shaded circuit diagrams.

The ZIP download contains a single printable 185-page PDF. The total includes the front and back covers, the copyright page, eight blank or header-only pages, and the 17-page appendix.

Engine Overhaul, Chassis Service, and Electrical Diagnosis

These selected workshop procedures show the scope of the manual. It also covers exhaust leak inspection and headlight aiming.

• Periodic service: Maintenance and lubrication intervals, body-panel access, compression testing, air-cleaner and fuel-line checks, transmission oil changes, and battery, fuse, and spark plug service.

• Engine and drivetrain: Engine removal and refitting, cylinder and piston inspection, crankcase and crankshaft work, and service of the kick-start mechanism, clutch, transmission, and drive axle.

• Carburetor and Autolube: Carburetor removal and teardown, jet and float inspection, fuel-cock testing, reed-valve service, idle and throttle-cable adjustment, and oil-pump air bleeding.

• Wheels, brakes, and steering: Front and rear wheel service, drum and brake-shoe wear checks, front fork and steering-column disassembly, bearing-race replacement, and rear shock inspection.

• Electrical troubleshooting: Circuit diagrams and fault charts for the electric starter, CDI ignition, charging, lighting, and signals, with component checks and a full wiring diagram.

• Workshop references: Exploded assemblies, cable-routing drawings, component torque tables, fluid capacities, clearances, wear limits, electrical test specifications, and Yamaha special-tool numbers.

Yamaha wrote this manual primarily for its dealers and qualified mechanics who already understand scooter repair procedures.

Engine and Drivetrain Bench Work

The overhaul chapter covers cylinder-head warpage, cylinder bore and piston-ring wear, crankshaft runout, and connecting-rod play. The drivetrain sections cover the wet centrifugal clutch, including shoe and spring checks, plus the drive chain, sprockets, and bearings. Reassembly drawings identify lubrication points, oil-seal orientation, and fastener-specific torques for the starter clutch, CDI magneto, and other assemblies.

The special-tool list lets you plan crankcase and flywheel work before teardown. It identifies the YU-01235 flywheel holder, YM-01189 magneto puller, YU-01135 crankcase separator, and YU-90050 crankshaft installation set. The overhaul chapter flags two sealing risks: damage to the crankcase mating faces during separation and damage to the oil-seal lip from the drive-axle threads or splines.

Carburetor and Oil Injection

The section view of the Y12P Teikei Kikaki carburetor distinguishes the main, slow, and starter metering circuits. The repair chapter covers the throttle valve, jet needle and clip, float, and needle valve. The Autolube sections cover pump-drive inspection and explain when the separate oil-injection system needs bleeding, including after the tank runs dry or an oil line is disconnected.

Chassis Access and Reassembly

Bodywork instructions cover the tail cover and side panels, footrest board, front panel, leg shield, and handlebar covers. The front fork and steering drawings show the bearing races and identify the YU-33975 ring-nut wrench used for adjustment. The manual calls for secure support during engine and front-end removal.

Starting, Ignition, and Signal Faults

The no-crank chart separates starter relay, brake-switch, and starter-motor faults. The manual gives brush, commutator, and armature checks and specifies assembly replacement for the starter motor. The no-spark chart covers the CDI magneto, ignition coil, and switches. Ignition timing is listed as nonadjustable.

The electrical chapter also traces faults in the horn, turn signals, brake light, fuel gauge, and oil-warning light. Component-location drawings and the wiring diagram help match the test points in the flowcharts to the scooter's connectors. The tool references identify the YU-03112 Pocket Tester and YU-33260 Electro Tester.

Sample Compression, Carburetor, and Charging Specs

The general specifications distinguish the variants by compression ratio: 6.9:1 for the SH50T and 6.3:1 for the SH50MT.

The Y12P carburetor inspection lists a factory-set float height of 15.0–17.0 mm (0.59–0.67 in). An out-of-range reading directs the inspection to the float, needle valve, and valve seat.

The charging-system flowchart specifies 0.7–0.9 A at 4,000 rpm for the charging-current test.