Yamaha CZD300J Owner'S Manual Download

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Perio

ic maintenance an

justment

8-13

EAU20071

Coolant

The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.

EAU78580

To check the coolant level

1. Place the vehicle on the center-

stand.

TIP



The coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.



Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.

2. Check the coolant level through

the check window.

TIP

The coolant should be between the mi-
nimum and maximum level marks.

3. If the coolant is at or below the mi-

nimum level mark, remove the left
floorboard mat by pulling it up.

4. Remove the coolant reservoir cov-

er.

5. Remove the coolant reservoir cap,

add coolant to the maximum level
mark, and then install the reservoir
cap.

WARNING! Remove only

the coolant reservoir cap. Never
attempt to remove the ra

iator

cap when the en

ine is hot.

[EWA15162]

NOTICE:

If coolant is not

availa

le, use

istille

water or

soft tap water instea

. Do not

use har

water or salt water

since it is harmful to the en

ine.

If water has

een use

instea

of coolant, replace it with cool-
ant as soon as possi

le, other-

wise the coolin

system will not

1. Coolant level check window
2. Maximum level mark
3. Minimum level mark

2
3

1. Floorboard mat

1. Coolant reservoir cover

UB7410E0.book Page 13 Tuesday, May 30, 2017 3:08 PM

Summary of Contents for CZD300J

Page 1: ...DIC183 OWNER S MANUAL CZD300J B74 F8199 10 LIT 11626 31 28 XMAX MOTORCYCLE Read this manual carefully before oper ating this vehicle ...

Page 2: ...EAU10043 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold UB7410E0 book Page 1 Tuesday May 30 2017 3 08 PM ...

Page 3: ...mportant that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual Yamaha continually seeks advancements in product design and quality There fore 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 ma...

Page 4: ...tes a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehi cle or other property A TIP provides key information to make proce dures easier or clearer CZD300J OWNER S MANUAL 2017 by Yamaha Motor Corporation U S A 1st edition May 2017 All rights reserved Any reprinting or unauthorized us...

Page 5: ...system 5 26 Auxiliary DC jack 5 28 For your safety pre operation checks 6 1 Operation and important riding points 7 1 Starting the engine 7 2 Starting off 7 3 Acceleration and deceleration 7 3 Braking 7 4 Tips for reducing fuel consumption 7 4 Engine break in 7 5 Parking 7 5 Periodic maintenance and adjustment 8 1 Owner s tool kit 8 2 Periodic maintenance chart for the emission control system 8 3 ...

Page 6: ... plate light bulb 8 34 Troubleshooting 8 35 Troubleshooting charts 8 36 Emergency mode 8 38 Scooter care and storage 9 1 Matte color caution 9 1 Care 9 1 Storage 9 4 Specifications 10 1 Consumer information 11 1 Identification numbers 11 1 Diagnostic connector 11 2 Vehicle data recording 11 2 Reporting safety defects 11 3 Scooter noise regulation 11 4 Maintenance record 11 5 YAMAHA MOTOR CORPORATI...

Page 7: ... They contain important in formation for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 2 3 1 4 5 6 7 8 9 UB7410E0 book Page 1 Tuesday May 30 2017 3 08 PM ...

Page 8: ...gasoline or solvent will damage windshield Use neutral detergent B74 F815K 00 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open B74 F2259 10 FUEL TANK THROTTLE BODY ATMOSPHERE CANISTER EMISSION HOSE ROUTING B74 F1686 00 WARNING Improper loading can cause loss of control Read owner s manual f...

Page 9: ... F1668 10 TIRE INFORMATION Cold tire normal pressure should be set as follows Up to 90 kg 198 lbs load FRONT REAR 200 kPa 2 00 kgf cm 29 psi 225 kPa 2 25 kgf cm 33 psi 90kg 198 lbs maximum load FRONT REAR 200 kPa 2 00 kgf cm 29 psi 225 kPa 2 25 kgf cm 33 psi 7 8 9 UB7410E0 book Page 3 Tuesday May 30 2017 3 08 PM ...

Page 10: ...ion Failure to inspect or maintain the vehi cle properly increases the possibility of an accident or equipment damage See page 6 1 for a list of pre operation checks This scooter is designed to carry the operator and a passenger The failure of motorists to detect and recognize scooters in traffic is the predominating cause of auto mobile scooter accidents Many accidents have been caused by an auto...

Page 11: ...s 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 inju ries The use of a safety helmet is the single most critical factor in the pre vention or reduction of head injuries Always wear an approved helmet Wear a face shi...

Page 12: ...ccessories Here along with the information about accessories be low are some general guidelines to fol low if loading cargo to your scooter The total weight of the operator pas senger accessories and cargo must not exceed the maximum load limit Operation of an overloaded vehicle could cause an accident When loading within this weight limit keep the following in mind Cargo and accessory weight shou...

Page 13: ...delines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the per formance of your scooter Careful ly 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 ob scure lights or refle...

Page 14: ...ble so that the scooter will not bounce exces sively during transport EAU57600 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 corner or turn Once you have completed a turn accelerate slowly Be ...

Page 15: ...e 8 14 5 Spring preload adjuster page 5 25 6 Final transmission oil filler cap page 8 12 7 Final transmission oil drain bolt page 8 12 8 V belt case air filter element page 8 14 9 Engine oil drain bolt page 8 9 10 Engine oil filter element page 8 9 11 Sidestand page 5 26 12 Spark plug page 8 8 13 Coolant reservoir page 8 13 UB7410E0 book Page 1 Tuesday May 30 2017 3 08 PM ...

Page 16: ...ent page 5 20 2 Fuel tank cap page 5 16 3 Storage compartment B page 5 20 4 Windshield page 5 22 5 Battery page 8 29 6 Fuses page 8 30 7 Centerstand page 8 27 8 Engine oil level check window page 8 9 9 Engine oil filler cap page 8 9 UB7410E0 book Page 2 Tuesday May 30 2017 3 08 PM ...

Page 17: ...r brake fluid reservoir page 8 23 4 Speedometer page 5 2 5 Multi function display page 5 3 6 Tachometer page 5 3 7 Front brake fluid reservoir page 8 23 8 Right handlebar switches page 5 11 9 Front brake lever page 5 13 10 Throttle grip page 8 18 11 Main switch page 4 8 12 Auxiliary DC jack page 5 28 UB7410E0 book Page 3 Tuesday May 30 2017 3 08 PM ...

Page 18: ...acturer before us ing this vehicle NOTICE ECA24080 The smart key system uses weak ra dio waves The smart key system may not work in the following situa tions The smart key is placed in a lo cation exposed to strong radio waves or other electromagnetic noise There are facilities nearby that are emitting strong radio waves TV or radio towers power plants broadcasting stations airports etc You are ca...

Page 19: ... simply push the main switch knob to turn the smart key system back on EAU66881 Part 15 of FCC Rules This device complies with Part 15 of FCC Rules Operation is subject to the following two conditions 1 this device may not cause interfer ence and 2 this device must accept any inter ference including interference that may cause undesired operation of this device FCC WARNING Changes or modifications...

Page 20: ...le will not recognize the smart key even if it is within oper ating range If the smart key sys tem does not operate see page 4 6 and confirm that the smart key is turned on Placing the smart key in the front or rear storage compartment may block communication between the smart key and the vehicle If the rear storage compartment is locked with the smart key inside the smart key system may be dis ab...

Page 21: ...o operate the vehicle in emergency mode See page 8 38 Write down the identifi cation number in case of emergen cy If the smart key is lost and the smart key system identification number is un known the entire smart key system will need to be replaced at considerable cost Keep the identification number card in a safe place NOTICE ECA21573 The smart key has precision elec tronic components Observe t...

Page 22: ...key battery when the smart key system indi cator light flashes for 20 seconds when the vehicle is turned on or when the smart key indicator light does not come on when the smart key button is pushed See page 4 7 After changing the smart key battery if the smart key system still does not operate check the vehicle battery and then have a Yamaha dealer check the vehicle If the smart key continually r...

Page 23: ...ush the smart key button to operate the answer back function remotely The beeper will sound twice and all of the turn signal lights will flash twice This feature is convenient for locating your vehicle in a parking lot and other areas To turn the answer back beeper on or off The beeper which sounds when the answer back function is operated can be turned on or off according to the fol lowing proced...

Page 24: ...ther heat sources NOTICE ECA15784 Use a cloth when opening the smart key case with a screw driver Direct contact with hard objects may damage or scratch the smart key Take precautions to prevent the waterproof seal from being damaged or contaminated by dirt Do not touch the internal cir cuits and terminals This may cause malfunctions Do not apply excessive force to the smart key when replacing the...

Page 25: ...nd open the seat fuel tank cap lid and storage compartment A After pushing the main switch knob and confirmation with the smart key has taken place the main switch can be turned while the smart key system indicator light is on approximately 4 seconds WARNING EWA18720 Never turn the main switch to OFF or OPEN while the ve hicle is moving Otherwise the elec Specified battery CR2032 1 Battery 1 1 Mai...

Page 26: ...ehicle power on 1 Turn the smart key on and bring it within operating range 2 Push the main switch knob and the smart key indicator light will come on for approximately 4 sec onds 3 While the smart key system indi cator light is on turn the main switch to ON All of the turn sig nal lights flash twice and the vehi cle power turns on TIP If the vehicle battery voltage is low the turn signal lights w...

Page 27: ...icle power off im mediately push the main switch knob four times within 2 seconds EAU79042 OPEN open Power is supplied to the main switch The seat and storage compartment A can be opened To open the seat and storage compart ment A 1 With the smart key turned on and within operating range push the main switch knob 2 While the smart key system indi cator light is on turn the main switch to OPEN 3 To...

Page 28: ...ounds after 3 minutes turn the main switch to OFF or If the beeper sounds because the smart key was turned off or moved out of range turn the smart key on and walk back into range TIP The beeper will turn off after 1 mi nute The seat can also be opened with the mechanical key See page 5 20 EAU76521 lock The steering is locked and all electrical systems are off To lock the steering 1 Turn the handl...

Page 29: ...ank cap lid To open the fuel tank cap lid 1 With the smart key turned on and within operating range push the main switch knob 2 While the smart key system indi cator light is on turn the main switch to To close the fuel tank cap lid Push the fuel tank cap lid down until it is closed TIP Make sure that fuel tank cap lid is se curely closed before starting off 1 Push 2 Push and turn 1 Push 2 Turn 1 ...

Page 30: ... when the main switch is turned to ON and goes off after trav eling at a speed of 10 km h 6 mi h or higher If the ABS warning light does not come on when the main switch is turned to ON comes on or flashes while riding does not go off after traveling at a speed of 10 km h 6 mi h or high er The ABS may not work correctly If any of the above occurs have a Yamaha dealer check the system as soon as po...

Page 31: ...few seconds and then go off If the light does not come on or if the light remains on have a Yamaha dealer check vehicle EAU78600 Smart key system indicator light This indicator light communicates the status of the smart key system When the smart key system is operating nor mally this indicator light will be off If there is an error in the smart key sys tem the indicator light will flash The indica...

Page 32: ... sure to stop the vehicle before making any setting changes to the multi function meter unit Changing settings while riding can distract the operator and increase the risk of an accident The TRIP INFO switch is located on the right side of the handlebar This switch allows you to control or change the settings of the multi function meter unit To use the TRIP switch move the TRIP INFO switch in dire...

Page 33: ...onds The hour digits will start flashing 4 Use the TRIP switch to set the hours 5 Push the TRIP switch for three seconds and then release it The minute digits will start flashing 6 Use the TRIP switch to set the minutes 7 Push the TRIP switch for three seconds and then release it to start the clock Fuel meter The fuel meter indicates the amount of fuel in the fuel tank The segments of the fuel met...

Page 34: ...hicle as soon as pos sible The coolant temperature varies with changes in the weather and engine load Tripmeter display The tripmeter display is equipped with the following odometer tripmeter time tripmeter fuel reserve tripmeter oil change tripmeter V belt replacement tripmeter Push the TRIP switch to change the display between the odometer Odo tripmeter Trip time tripmeter Trip Time oil change t...

Page 35: ...and start counting the distance traveled from that point In this case push the TRIP switch to switch the display in the fol lowing order F Trip Oil Trip V Belt Trip Odo Trip Trip Time F Trip To reset the fuel reserve tripmeter se lect it by pushing the TRIP switch and then push the TRIP switch for three seconds The fuel reserve tripmeter will reset au tomatically and disappear after refuel ing and...

Page 36: ...replaced After replacing the V belt reset the V belt replacement indicator and the V belt replacement tripmeter To reset them both select the V belt replace ment tripmeter and then push the TRIP switch for three seconds While the V belt replacement tripmeter is flashing push the TRIP switch for 15 to 20 seconds Release the TRIP switch and the V belt trip value will re set to zero TIP If the V belt...

Page 37: ...verage Air temp TIP When kilometers are selected for the display units Consump tion Average_ _ _ _MPG and Consumption_ _ _ _MPG are not displayed When miles are selected for the display units Consump tion Average_ _ _ km L Con sumption Average_ _ _ L 100 km Consumption_ _ _ km L and Consumption_ _ _ L 100 km are not displayed Air temperature display This display shows the air temperature from 14 F...

Page 38: ...sumption since it was last re set The average fuel consumption can be displayed as either Consump tion Average_ _ _ km L Consump tion Average_ _ _ L 100 km or Consumption Average_ _ _ _ MPG Consumption Average_ _ _ km L The average distance that can be traveled on 1 0 L of fuel is shown Consumption Average_ _ _ L 100 km The average amount of fuel necessary to travel 100 km is shown Consumption Ave...

Page 39: ...erage_ _ _MPH is displayed The average speed is the total distance divided by the total time with the main switch in the ON position since the display was last reset to zero This display shows the average speed since it was last reset To reset the average speed display select it by pushing the INFO switch and then push the INFO switch for three seconds Warning message function This function displa...

Page 40: ...ing messages are displayed in the following order L FUEL H TEMP ICE OIL SERV VBELT SERV L FUEL EAU1234M Handlebar switches Left Right EAU54201 Dimmer Pass switch PASS Set this switch to for the high beam and to for the low beam To flash the high beam push the pass side PASS of the switch while the headlights are on low beam EAU12461 Turn signal switch To signal a right hand turn push this switch t...

Page 41: ...the main switch in the ON posi tion use this switch to turn on the haz ard lights simultaneous flashing of all turn signal lights The hazard lights are used in case of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard NOTICE ECA10062 Do not use the hazard lights for an extended length of time with the en gine not running otherwise the bat tery ma...

Page 42: ...handlebar To apply the front brake pull this lever toward the throttle grip EAU12952 Rear brake lever The rear brake lever is located on the left side of the handlebar To apply the rear brake pull this lever toward the handlebar grip 1 Front brake lever 1 1 Rear brake lever 1 UB7410E0 book Page 13 Tuesday May 30 2017 3 08 PM ...

Page 43: ...an ECU which will revert the system to conven tional braking if a malfunction occurs TIP The ABS performs a self diagno sis test each time the vehicle first starts off after the main switch is turned to ON and the vehicle has traveled at a speed of 10 km h 6 mi h or higher During this test a clicking noise can be heard from the front of the vehicle and if ei ther brake lever is even slightly ap pl...

Page 44: ...surfaces Setting the traction control system When the vehicle is turned on traction control is automatically turned on To turn the traction control system off use the INFO switch to change the information display to the traction con trol system display Then push the IN FO switch for three seconds The display will show TCSOFF and the TCS indicator light will come on TIP Turn the traction control sy...

Page 45: ... abled TIP If the indicator light remains on af ter resetting the vehicle may still be ridden however have a Yamaha deal er check the vehicle as soon as possi ble 4 Have a Yamaha dealer check the vehicle and turn off the warning light EAU78502 Fuel tank cap To remove the fuel tank cap 1 Turn the main switch to to open the fuel tank cap lid 2 Turn the fuel tank cap counter clockwise until the relea...

Page 46: ...off the en gine and be sure that no one is sit ting on the vehicle Never refuel while smoking or while in the vi cinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank Stop filling when the fuel reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engine or the sun c...

Page 47: ...uch as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use unleaded gasoline with a pump octane number R M 2 of 86 or higher or 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 Gasohol ...

Page 48: ...erters in the exhaust system WARNING EWA10863 The exhaust system is hot after op eration To prevent a fire hazard or burns Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn Park the vehicle in a place where pedestrians or children are not likely to touch the hot exhaust system Make sure that the exhaust sys tem has cooled down before doing any mai...

Page 49: ...itch to OPEN and then push the LID button To close storage compartment A push the storage compartment lid until it is closed Storage compartment B To open storage compartment B push the storage compartment lid inward to unlock it and then pull to open To close storage compartment B push the storage compartment lid into the original position Seat rear storage compartment To open the seat rear stora...

Page 50: ...ms inside it To avoid humidity from spread ing through the storage com partment wrap wet articles in a plastic bag before storing them in the compartment Since the storage compartment may get wet while the vehicle is being washed wrap any articles stored in the compartment in a plastic bag Do not keep anything valuable or breakable in the storage compartment WARNING EWA18950 Do not exceed the load...

Page 51: ...he windshield by remov ing the bolts 3 Remove the bolts and then install the bolts in the desired position 4 Install the windshield to the high position by installing the bolts and then tighten the bolts to the spec ified torque WARNING A loose windshield could cause an acci dent Be sure to tighten the screws to the specified torque EWA15511 1 Windshield 1 Quick fastener 2 Bolt access cover 1 2 1 ...

Page 52: ...move the bolts and then install the bolts in the desired position 4 Install the windshield to the low position by installing the bolts and then tighten the bolts to the spec ified torque WARNING A loose windshield could cause an acci dent Be sure to tighten the screws to the specified torque EWA15511 1 Bolt Tightening torque Windshield bolt 8 N m 0 8 kgf m 5 9 lb ft 1 Bolt access cover 1 1 1 1 Bol...

Page 53: ...teners EAU46833 Handlebar position The handlebar can be adjusted to one of two positions to suit the rider s pref erence Have a Yamaha dealer adjust the position of the handlebar Tightening torque Windshield bolt 8 N m 0 8 kgf m 5 9 lb ft 1 Handlebar 1 UB7410E0 book Page 24 Tuesday May 30 2017 3 08 PM ...

Page 54: ... spring preload and thereby harden the suspension turn the adjusting ring on each shock ab sorber assembly in direction a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring on each shock absorber as sembly in direction b Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber Use the spring preload adjusting tool ...

Page 55: ...sulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly and have a Yamaha dealer repair it if it does not function properly EAU78690 Ignition circuit cut off system The ignition circuit cut off system works with the si...

Page 56: ...ll The system is OK The vehicle can be ridden The sidestand switch may not be working correctly The vehicle should not be ridden until checked by a Yamaha dealer The brake switch may not be working correctly The vehicle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The vehicle should not be ridden until checked by a Yamaha dealer WARNING Th...

Page 57: ... is equipped with an auxil iary DC jack located within storage compartment A A 12 V accessory connected to the auxiliary DC jack can be used when the main switch is in the ON position and should only be used when the engine is running To use the auxiliary DC jack 1 Open storage compartment A See page 4 10 2 Turn the main switch off 3 Remove the auxiliary DC jack cap 4 Turn the accessory off 5 Inse...

Page 58: ...sary add recommended oil to specified level Check vehicle for oil leakage 8 9 Final transmission oil Check vehicle for oil leakage 8 12 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 8 13 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if nece...

Page 59: ...oting points if necessary 8 26 Centerstand side stand Make sure that operation is smooth Lubricate pivots if necessary 8 27 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off system If system is not working cor...

Page 60: ...could cause an accident or injury EAU78221 TIP This model is equipped with a lean an gle sensor to stop the engine in case of a turnover In this case the engine trouble warning light will come on but this is not a malfunction Before re starting the engine turn the main switch off and then back on to reset the engine trouble warning light Failing to do so will prevent the engine from starting even ...

Page 61: ...ey system indicator light TIP The ABS warning light should come on and stay on until the vehicle reaches a traveling speed of 10 km h 6 mi h or higher NOTICE ECA22510 If a warning or indicator light does not work as described above see page 5 1 for the corresponding warning and indicator light circuit check 2 Close the throttle 3 While applying the front or rear brake push the side of the stop run...

Page 62: ...mirrors 3 Switch the turn signals on 4 Check for oncoming traffic and then slowly turn the throttle grip on the right in order to take off 5 Switch the turn signals off EAU16782 Acceleration and deceleration The speed can be adjusted by opening and closing the throttle To increase the speed turn the throttle grip in di rection a To reduce the speed turn the throttle grip in direction b 1 Grab bar ...

Page 63: ...more difficult Ride slowly down a hill as brak ing downhill can be very diffi cult 1 Close the throttle completely 2 Apply both front and rear brakes simultaneously while gradually in creasing the pressure EAU16821 Tips for reducing fuel con sumption Fuel consumption depends largely on your riding style Consider the follow ing tips to reduce fuel consumption Avoid high engine speeds during acceler...

Page 64: ...ould oc cur during the engine break in period immediately have a Yamaha dealer check the vehi cle EAUN1421 Parking When parking turn the vehicle power off and then turn the smart key off TIP Even when the vehicle is parked in a lo cation partitioned by a fence or the glass window of a shop if the smart key is within operating range other people will be able to start the engine and operate the vehi...

Page 65: ...Operation and important riding points 7 6 7 Do not park near grass or other flammable materials which might catch fire UB7410E0 book Page 6 Tuesday May 30 2017 3 08 PM ...

Page 66: ...maintain the vehi cle or performing maintenance ac tivities incorrectly may increase your risk of injury or death during service or while using the vehicle If you are not familiar with vehicle ser vice have a Yamaha dealer perform service WARNING EWA15123 Turn off the engine when performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clo...

Page 67: ... that is certified if applicable Yamaha dealers are trained and equipped to perform these particular services EAU79250 Owner s tool kit The owner s tool kit is located on the bottom of the seat See page 4 10 The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How eve...

Page 68: ...e Check fuel hoses for cracks or damage Replace if necessary 2 Spark plug Check condition Adjust gap and clean Replace Every 12000 mi 19000 km 3 Valve clearance Check and adjust Every 12000 mi 19000 km 4 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Fuel injection Check engine idle speed 6 Exhaust system Check for leakage Tighten if necessary Replace gas...

Page 69: ...er element Clean 7 Front brake Check operation fluid level and for fluid leakage Replace brake pads if neces sary 8 Rear brake Check operation fluid level and for fluid leakage Replace brake pads if neces sary 9 Brake hoses Check for cracks or damage Check for correct routing and clamping Replace Every 4 years 10 Brake fluid Change Every 2 years 11 Wheels Check runout and for damage Replace if nec...

Page 70: ... oil leakage Replace if necessary 21 Shock absorber as semblies Check operation and for oil leakage Replace if necessary 22 Engine oil Check oil level and vehicle for oil leakage Change When the oil change indicator flashes 23 Engine oil filter ele ment Replace Every 12000 mi 19000 km 24 Cooling system Check coolant level and vehicle for coolant leakage Change coolant Every 3 years 25 Final transm...

Page 71: ... levels and replenish the reservoirs as need ed Replace the internal components of the brake master cylinders and cali pers and change the brake fluid every two years Replace the brake hoses every four years or sooner if cracked or damaged 29 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip hous ing 30 Lights signals and switches Check op...

Page 72: ...is chapter Refer to this section each time the panel needs to be removed and installed EAU78530 Panel A To remove the panel Remove the screws and then pull the panel outward and slide it forward as shown To install the panel Place the panel in the original position and then install the screws 1 Panel A 1 Screw 1 1 1 1 Panel A 1 UB7410E0 book Page 7 Tuesday May 30 2017 3 08 PM ...

Page 73: ...ot attempt to diagnose such problems yourself Instead have a Yamaha deal er check the vehicle If the spark plug shows signs of elec trode erosion and excessive carbon or other deposits it should be replaced Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Clean the surface of the spark plug gasket and its ma...

Page 74: ...d the oil filter ele ment replaced at the intervals specified in the periodic maintenance and lubri cation chart To check the engine oil level 1 Place the vehicle on a level surfa ce and hold it in an upright posi tion A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then c...

Page 75: ...ect the used oil 3 Remove the engine oil filler cap and its O ring and then remove the engine oil drain bolt and its gasket to drain the oil from the crankcase 4 Check the O ring for damage and replace it if necessary TIP Skip steps 5 7 if the oil filter element is not being replaced 5 Remove the oil filter element cover by removing the bolts 6 Remove and replace the oil filter element and O ring ...

Page 76: ...reign material enters the crankcase 10 Install and tighten the oil filler cap and its O ring 11 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 12 Turn the engine off and then check the oil level and correct it if necessary 1 Oil filter element 2 O ring Tightening torque Oil filter...

Page 77: ...mission oil drain bolt and its gasket to drain the oil from the final transmission case 6 Install the final transmission oil drain bolt and its new gasket and then tighten the bolt to the speci fied torque 7 Refill with the specified amount of the recommended final transmis sion oil WARNING Make sure that no foreign material enters the final transmission case Make sure that no oil gets on the tire...

Page 78: ...mum and maximum level marks 3 If the coolant is at or below the mi nimum level mark remove the left floorboard mat by pulling it up 4 Remove the coolant reservoir cov er 5 Remove the coolant reservoir cap add coolant to the maximum level mark and then install the reservoir cap WARNING Remove only the coolant reservoir cap Never attempt to remove the radiator cap when the engine is hot EWA15162 NOT...

Page 79: ...ent and the sub air fil ter element should be replaced and the pre air filter element and the V belt case air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Service the air filter elements more frequently if you are riding in un usually wet or dusty areas The air filter check hose must be frequently checked and cleaned if necessary Cle...

Page 80: ...ase cover 6 Insert a new air filter element into the air filter case NOTICE Make sure that the air filter element is properly seated in the air filter case The engine should never be operated without the air filter element installed otherwise the piston s and or cylinder s may become excessively worn ECA10482 7 Pull the pre air filter element out and then blow out the dirt with compressed air as s...

Page 81: ...g the screws TIP The long screw should be installed as shown 11 Install the rubber plugs Cleaning the V belt case air filter el ement 1 Place the vehicle on the center stand 2 Remove the air filter case cover See the previous section 3 Remove the V belt case cover screws 4 Remove the air filter case bolts 1 Pre air filter element 2 Air filter case cover 1 2 1 Long screw 1 Screw 1 1 1 UB7410E0 book...

Page 82: ...r from the clean side as shown 8 Check the V belt case air filter ele ment for damage and replace it if necessary 9 Insert the element into the V belt case 10 Install the V belt case air filter cov er by installing the bolts 11 Install the rear wheel sensor lead into the holder at the white tape on the lead as shown 1 Bolt 1 Rear wheel sensor lead 2 Lead holder 1 V belt case air filter cover 2 Bol...

Page 83: ... the screws EAU21386 Checking the throttle grip free play Measure the throttle grip free play as shown Periodically check the throttle grip free play and if necessary have a Yamaha dealer adjust it 1 Rear wheel sensor lead 2 White tape 3 Lead holder Tightening torque Bolt 10 N m 1 0 kgf m 7 4 lb ft 1 3 3 2 2 3 2 2 3 1 Throttle grip free play Throttle grip free play 3 0 5 0 mm 0 12 0 20 in 1 UB7410...

Page 84: ... in all con ditions of riding depends on a relatively small area of road contact Therefore it is essential to maintain the tires in good condition at all times and replace them at the appropriate time with the speci fied tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10504 Operation of this vehicle with im proper tire pressure ...

Page 85: ...d tire air valves Tires age even if they have not been used or have only been used occasion ally Cracking of the tread and sidewall rubber sometimes accompanied by carcass deformation is an evidence of ageing Old and aged tires shall be checked by tire specialists to ascertain their suitability for further use WARNING EWA10462 The front and rear tires should be of the same make and design other wi...

Page 86: ...aha dealer replace the wheel Do not attempt even the smallest repair to the wheel A de formed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Front tire Size 120 70 15 M C 56P Manufacturer model DUNLOP SCOOTSMA...

Page 87: ...WA14212 A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have a Yamaha dealer bleed the system be fore operating the vehicle Air in the hydraulic system will diminish the braking performance which may re sult in loss of control and an acci dent 1 No brake lever free play 1 No brake lever free play 1 1 UB741...

Page 88: ...wear indicator almost touches the brake disc have a Yamaha dealer re place the brake pads as a set EAU22583 Checking the brake fluid level Before riding check that the brake fluid is above the minimum level mark Check the brake fluid level with the res ervoir in an upright position Replenish the brake fluid if necessary NOTICE ECA17641 Brake fluid may damage painted surfaces or plastic parts Alway...

Page 89: ... a sealed container Use only the specified brake flu id otherwise the rubber seals may deteriorate causing leak age Refill with the same type of brake fluid Adding a brake fluid other than DOT 4 may result in a harmful chemical reaction Be careful that water does not enter the brake fluid reservoir when refilling Water will signifi cantly lower the boiling point of the fluid and may result in vapo...

Page 90: ... should be checked before each ride and the ca bles and cable ends should be lubri cated if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or re place it WARNING Damage to the outer housing of cables may result in internal rusting and cause inter ference with cable movement Re place damaged cables as soon as possible to prevent unsafe condi tions EWA10712 Reco...

Page 91: ...cat ed by a Yamaha dealer at the intervals specified in the periodic maintenance chart EAU23173 Lubricating the front and rear brake levers Front brake lever Rear brake lever The pivoting points of the front and rear brake levers must be lubricated at the intervals specified in the periodic main tenance and lubrication chart Recommended lubricant Silicone grease UB7410E0 book Page 26 Tuesday May 3...

Page 92: ...ration of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart To check the condition Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level surfa ce and hold it in an upright posi tion WARNING To avoid injury securely support the vehicle so there is no danger of it...

Page 93: ...hicle so there is no danger of it falling over EWA10752 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steer ing EAU23292 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is...

Page 94: ...nd pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quick ly if the vehicle is equipped with op tional electrical accessories NOTICE ECA16522 To charge a...

Page 95: ...roperly con nected to the battery terminals NOTICE ECA16531 Always keep the battery charged Storing a discharged battery can cause permanent battery damage EAU78242 Replacing the fuses The main fuse and the fuse boxes which contain the fuses for the individ ual circuits are located under panel A See page 8 7 TIP To access the main fuse remove the starter relay cover as shown 1 Fuse box 2 Main fuse...

Page 96: ...ice operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Signaling system fuse 2 ABS control unit fuse 3 Main fuse 2 4 Radiator fan motor fuse 5 Backup fuse 6 Spare fuse 7 ABS motor fuse 8 ABS solenoid fuse 9 Turn signal light and hazard fuse 10 Terminal fuse 1 11 Answer back fuse 1 2 3 4 5 6 7 8 9 10 11 6 Specified fuses Main fuse 30 0 A Main fuse 2 7 ...

Page 97: ...e on have a Yamaha dealer check its electrical circuit NOTICE ECA16581 Do not affix any type of tinted film or stickers to the headlight lens EAU54502 Auxiliary lights This model is equipped with LED type auxiliary lights If an auxiliary light does not come on have a Yamaha dealer check it UB7410E0 book Page 32 Tuesday May 30 2017 3 08 PM ...

Page 98: ... dealer check it EAU43006 Replacing a turn signal light bulb 1 Remove the turn signal light unit by removing the screw 2 Remove the turn signal light bulb socket together with the bulb by turning it counterclockwise 3 Remove the burnt out bulb by pulling it out 1 Turn signal light lens 2 Screw 1 Turn signal light bulb socket 1 2 1 UB7410E0 book Page 33 Tuesday May 30 2017 3 08 PM ...

Page 99: ...plate light unit by removing the bolts and plate and then remove the license plate light bulb socket together with the bulb by pulling it out 2 Remove the burnt out bulb by pulling it out 3 Insert a new bulb into the socket 4 Install the socket together with the bulb by pushing it in and then install the license plate light unit by installing the plate and bolts 1 Turn signal light bulb 1 1 Licens...

Page 100: ...e no open flames or sparks in the ar ea including pilot lights from water heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or prop erty damage EAU76551 Smart key system troubleshooting Please check the following items when the smart key system does not work Is the smart key turned on See page 4 6 Is the smart key battery dis charged See page 4 7 Is the s...

Page 101: ...e battery lead connections and have a Yamaha dealer charge the battery if necessary 2 Battery The battery is good The engine does not start Check the ignition 3 Ignition Wet Dry There is compression There is no compression The engine does not start Have a Yamaha dealer check the vehicle Have a Yamaha dealer check the vehicle The engine does not start Check the compression Have a Yamaha dealer chec...

Page 102: ...pped press down on the cap while turning it counterclockwise and then remove the cap TIP If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator Add coolant See TIP The coolant level is OK There is no leakage There is leakag...

Page 103: ...three seconds to indicate the transition to emergency mode 3 After the smart key system indica tor light goes off input the identifi cation number as follows 4 Inputting the identification number is done by counting the number of flashes of the smart key system in dicator light For example if the identification number is 123456 Push and hold the knob The smart key system indicator light will start...

Page 104: ... will flash quickly for 3 seconds In this case start over again from step 2 When there are no knob opera tions for 10 seconds during the identification number input pro cess When the smart key system indi cator light is allowed to flash nine or more times The identification number is not entered correctly 5 While the smart key system indi cator light is on push the knob once more to complete emerg...

Page 105: ... appearance of a scooter Fre quent and proper care does not only comply with the terms of the warranty but it will also keep your scooter look ing good extend its life and optimize its performance Before cleaning 1 Cover the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and cov ers as well as all electrical cou plers and connectors including the spark...

Page 106: ...hield Do not use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning compounds for plastic may leave scratches on the wind shield Test the product on a small hidden part of the wind shield to make sure that it does not leave any marks If the wind shield is scratched use a quality plastic polishing compound af ter washing After normal use Remove dirt with warm wat...

Page 107: ...y oil as a universal clean er to remove any remaining dirt 5 Touch up minor paint damage caused by stones etc 6 Wax all painted surfaces 7 Let the scooter dry completely be fore storing or covering it WARNING EWA10943 Contaminants on the brakes or tires can cause loss of control Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a...

Page 108: ...plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder wall with oil e Remove the spark plug cap from the spark plug and then install the spark plug and the spark plug cap WARNING To prevent damage or injury from sparking make sure to...

Page 109: ...Scooter care and storage 9 5 9 TIP Make any necessary repairs before storing the scooter UB7410E0 book Page 5 Tuesday May 30 2017 3 08 PM ...

Page 110: ...higher JASO standard MA or MB Engine oil quantity Oil change 1 50 L 1 59 US qt 1 32 Imp qt With oil filter removal 1 60 L 1 69 US qt 1 41 Imp qt Final transmission oil Type Motor oil SAE 10W 30 type SE or higher or Gear oil SAE 85W GL 3 Quantity 0 20 L 0 21 US qt 0 18 Imp qt Coolant quantity Coolant reservoir up to the maximum level mark 0 18 L 0 19 US qt 0 16 Imp qt Radiator including all routes ...

Page 111: ...0 kg 198 lb load Front 200 kPa 2 00 kgf cm 29 psi Rear 225 kPa 2 25 kgf cm 33 psi 90 kg 198 lb load maximum load Front 200 kPa 2 00 kgf cm 29 psi Rear 225 kPa 2 25 kgf cm 33 psi Front wheel Wheel type Cast wheel Rim size J15M C x MT3 5 Rear wheel Wheel type Cast wheel Rim size J14M C x MT4 0 Front brake Type Hydraulic single disc brake Specified brake fluid DOT 4 Rear brake Type Hydraulic single d...

Page 112: ...ndicator light LED Engine trouble warning light LED ABS warning light LED Smart key system indicator light LED Traction control system indicator warning light LED Fuse s Main fuse 30 0 A Main fuse 2 7 5 A Terminal fuse 1 2 0 A Signaling system fuse 10 0 A Radiator fan motor fuse 7 5 A Turn signal light and hazard fuse 7 5 A ABS control unit fuse 7 5 A ABS motor fuse 30 0 A ABS solenoid fuse 15 0 A...

Page 113: ...e vehicle identification number is stamped into the frame TIP The vehicle identification number is used to identify your vehicle and may be used to register it with the licensing authority in your area EAU26442 Engine serial number The engine serial number is stamped into the crankcase EAU26501 Model label The model label is affixed to the inside of the rear storage compartment See page 5 20 Recor...

Page 114: ...h as when maintenance checks or service procedures are performed Although the sensors and recorded data will vary by model the main data points are Vehicle status and engine perfor mance data Fuel injection and emission relat ed data Yamaha will not disclose this data to a third party except With the consent of the vehicle owner Where obligated by law For use by Yamaha in litigation For general Ya...

Page 115: ...it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Adminis trator NHTSA 1200 New Jersey...

Page 116: ...cle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or el ement of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification re moval etc ...

Page 117: ...s required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 24000 mi 37000 km or 36 months 28000 mi 43000 km or 42 months 32000 mi 49000 k...

Page 118: ... business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent purchaser it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer A reasonable dealer imposed fee may be charg...

Page 119: ...nd upon your request at any later date 3 Each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Q Is the warranty transferable to second owners A Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha motorcycle dealer for the policy to remain effective CUSTOMER SERV...

Page 120: ...ge limitations Coverage isn t limited to moving parts or the drivetrain like many other plans And Y E S covers manufacturing defects just like the warranty See the sample contract at your Yamaha dealer to see how comforting uninterrupted factory backed protection can be You don t have to pay anything for covered repairs There s no deductible to pay and repairs aren t pro rated You don t have any o...

Page 121: ...ked protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your VIN number and we ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 YAMAHA EXTENDED SERVICE UB7410E0 book Page 9 Tuesday May 30 2017 3 08 PM ...

Page 122: ...uses replacing 8 30 H Handlebar position adjusting 5 24 Handlebar switches 5 11 Hazard switch 5 12 Headlights 8 32 High beam indicator light 5 1 Horn switch 5 12 I Identification numbers 11 1 Ignition circuit cut off system 5 26 Indicator lights and warning lights 5 1 K Key handling of smart and mechanical keys 4 4 L Labels location 1 1 License plate light bulb replacing 8 34 M Main switch 4 8 Mai...

Page 123: ... Traction control system indicator light 5 2 TRIP INFO switch 5 12 Troubleshooting 8 35 Troubleshooting charts 8 36 Turn signal indicator lights 5 1 Turn signal light bulb replacing 8 33 Turn signal switch 5 11 V Valve clearance 8 19 V belt checking 8 25 Vehicle identification number 11 1 W Warranty extended 11 8 Warranty limited 11 6 Wheel bearings checking 8 28 Wheels 8 21 Windshield 5 22 UB7410...

Page 124: ...UB7410E0 book Page 3 Tuesday May 30 2017 3 08 PM ...

Page 125: ...rm right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha from the inside out Genuine Yamaha Service Manuals Get the same factory manual for your vehicle that the technicians at your authorized Yamaha dealer use Service ma...

Page 126: ...DIC183 PRINTED IN INDONESIA 2017 05 ...

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