Yamaha MAJESTY YP250A Owner'S Manual Download | Manualshive

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6-18

PERIODIC MAINTENANCE AND MINOR REPAIR

6

EAU04228

Final transmission oil

Final transmission oil

The final transmission case must be
checked for oil leakage before each
ride. If any leakage is found, have a
Yamaha dealer check and repair the
scooter. In addition, the final trans-
mission oil must be changed as fol-
lows at the intervals specified in the
periodic maintenance and lubrication
chart.

1. Start the engine, warm it up by

riding the scooter for several
minutes, and then stop the
engine.

2. Place the scooter on the center-

stand.

3. Place an oil pan under the final

transmission case to collect the
used oil.

EWA00062

w

8

8

Make sure that no foreign
material enters the final trans-
mission case.

8

8

Make sure that no oil gets on
the tire or wheel.

1

1.

Final transmission oil drain bolt

4. Remove the oil filler cap and

drain bolt to drain the oil from the
final transmission case.

5. Install the final transmission oil

drain bolt, and then tighten it to
the specified torque.

6. Add the specified amount of the

recommended final transmission
oil, and then install and tighten
the oil filler cap.

1

1.

Final transmission oil filler cap

Tightening torque:

Final transmission oil drain bolt:

22 Nm (2.2 m·kgf)

Recommended final transmission
oil:

See page 8-2.

Oil quantity:

0.25 L

5SJ-28199-E1 7/11/02 11:03 AM Page 67

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Summary of Contents for MAJESTY YP250A

Page 1: ...OWNER S MANUAL 5SJ 28199 E1 YP250A ...

Page 2: ...5SJ 28199 E1 7 11 02 11 03 AM Page 112 ...

Page 3: ...ghly so as to enjoy all advantages of your YP250A The owner s manual does not only instruct you in how to operate inspect and maintain your scooter but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your scooter in the best possible condi tion If you have any further questions do not hesitate to contact your Yamaha...

Page 4: ...taken to avoid damage to the scooter A NOTE provides key information to make procedures easier or clearer Q w cC NOTE NOTE 8 This manual should be considered a permanent part of this scooter and should remain with it even if the scooter is subsequently sold 8 Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product informatio...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 w PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS SCOOTER 5SJ 28199 E1 7 11 02 11 03 AM Page 3 ...

Page 6: ...aha Motor Co Ltd 1st edition June 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EAU04229 5SJ 28199 E1 7 11 02 11 03 AM Page 4 ...

Page 7: ...ION 3 INSTRUMENT AND CONTROL FUNCTIONS 4 PRE OPERATION CHECKS 5 OPERATION AND IMPORTANT RIDING POINTS 6 PERIODIC MAINTENANCE AND MINOR REPAIR 7 SCOOTER CARE AND STORAGE 8 SPECIFICATIONS 9 CONSUMER INFORMATION INDEX 9 8 7 6 5 4 3 2 1 5SJ 28199 E1 7 11 02 11 03 AM Page 5 ...

Page 8: ...5SJ 28199 E1 7 11 02 11 03 AM Page 6 ...

Page 9: ...GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY 1 1 Further safe riding points 1 2 1 5SJ 28199 E1 7 11 02 11 03 AM Page 7 ...

Page 10: ...even small amounts of alcohol there is a tendency to take dangerous risks Protective clothing is as essential for the scooter rider as seat belts are for car drivers and passen gers Always wear a complete motorcycle suit whether made of leather or tear resistant synthetic materials with protectors sturdy boots motorcycle gloves and a properly fitting helmet Optimum pro tective wear however should ...

Page 11: ...might not see you and open a door in your path 8 Railroad crossings streetcar rails iron plates on road construction sites and manhole covers become extremely slippery when wet Slow down and cross them with caution Keep the scooter upright otherwise it could slide out from under you 8 The brake pads could get wet when you wash the scooter After washing the scooter check the brakes before riding 8 ...

Page 12: ...5SJ 28199 E1 7 11 02 11 03 AM Page 10 ...

Page 13: ...DESCRIPTION Left view 2 1 Right view 2 2 Controls and instruments 2 3 2 5SJ 28199 E1 7 11 02 11 03 AM Page 11 ...

Page 14: ... bar page 5 2 3 Shock absorber spring preload adjusting ring page 3 21 4 Air filter element page 6 21 5 V belt case air filter element page 6 22 6 Centerstand page 6 31 7 Sidestand page 3 22 6 31 8 Fuel tank cap page 3 15 1 2 3 4 5 6 7 8 Left view 5SJ 28199 E1 7 11 02 11 03 AM Page 12 ...

Page 15: ...r page 6 23 12 Headlight page 6 37 13 Radiator 14 Battery page 6 34 15 Fuse box page 6 36 16 Coolant reservoir cap page 6 20 17 Coolant level check window page 6 19 18 Engine oil filler cap page 6 15 11 12 13 16 17 18 14 15 10 9 Right view 5SJ 28199 E1 7 11 02 11 03 AM Page 13 ...

Page 16: ... A page 3 19 4 Coolant temperature gauge page 3 5 5 Tachometer page 3 4 6 Speedometer page 3 4 7 Multi function display page 3 5 8 Fuel gauge page 3 5 9 Right handlebar switches page 3 11 10 Front brake lever page 3 11 11 Throttle grip page 6 23 6 31 12 Front storage compartment B page 3 20 13 Main switch steering lock page 3 1 5SJ 28199 E1 7 11 02 11 03 AM Page 14 ...

Page 17: ...on display 3 5 Anti theft alarm optional 3 10 Handlebar switches 3 10 Front brake lever 3 11 Rear brake lever 3 12 ABS 3 13 Fuel tank cap 3 15 Fuel 3 16 Catalytic converter 3 17 Rider seat 3 18 Adjusting the rider seat 3 18 Storage compartments 3 19 Adjusting the shock absorber assemblies 3 21 Sidestand 3 22 Ignition circuit cut off system 3 22 3 5SJ 28199 E1 7 11 02 11 03 AM Page 15 ...

Page 18: ...til the key is turned to OFF or the sidestand is moved down EAU00038 OFF All electrical systems are off The key can be removed EAU00040 LOCK The steering is locked and all electri cal systems are off The key can be removed To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF position and then turn it to LOCK while still pushing it 3 Remove the key To un...

Page 19: ...tive If this occurs have a Yamaha dealer check the electrical circuit See page 3 13 for an explanation of the ABS The electrical circuit of the warning light can be checked by setting the engine stop switch to and turning the key to ON The warning light should come on for a few seconds and then go off If the warning light does not come on or remains on have a Yamaha dealer check the electrical cir...

Page 20: ... every 3 000 km thereafter to indicate that the engine oil should be changed If the engine oil is changed before the oil change indicator comes on i e before the periodic oil change interval has been reached the indicator light must be reset after the oil change for the next periodic oil change to be indicated at the correct time See page 6 17 for the resetting proce dure The electrical circuit of...

Page 21: ... engine above 8 500 r min 8 8 This scooter is equipped with an engine speed limiter which prevents the engine speed from exceeding approximately 9 000 r min EAU04582 Tachometer Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the tachometer needle will move to the 10 000 r min and back to zero r mi...

Page 22: ...hanges in weather and engine load If the needle points to the red mark stop your scooter and let the engine cool See page 6 44 for details EC000002 cC Do not operate the engine if it is overheated 1 2 1 Coolant temperature gauge 2 Red mark EAU04906 Multi function display Display multi function The multi function display is equipped with the following 8 a tripmeter which shows the dis tance travele...

Page 23: ...ive sec onds To return to the reset mode push the SELECT but ton again until Trip begins flashing 8 To cancel the tripmeter reset mode push the SELECT but ton 8 If the tripmeter indicates have a Yamaha dealer check or repair the multi function display as it may be faulty Tripmeter Trip To reset the tripmeter 1 Push the SELECT button until the voltage display appears then push the SELECT button one...

Page 24: ...eter display automatically changes to the fuel trip meter mode Trip F and starts count ing the distance traveled from that point After refueling and traveling 5 km the odometer display returns to Odo To return to the odometer mode before refueling push the SELECT button until Trip F begins flashing Trip F will only flash for five sec onds While Trip F is flashing push the RESET button for at least...

Page 25: ... and RESET button together for at least two seconds 4 Push the SELECT button and the minute digits will start flash ing 5 Push the RESET button to set the minutes 6 Push the SELECT button and then release it to start the clock 3 When the hour digits start flash ing push the RESET button to set the hours 5SJ 28199 E1 7 11 02 11 03 AM Page 23 ...

Page 26: ...there is a problem with the electrical circuit Have a Yamaha dealer check or repair the electric circuit 8 The accuracy of the temperature reading may be affected when riding slowly approximately under 20 km h or when stopped at traffic signals railroad cross ings etc Voltage display This display shows the battery volt age ECA00135 cC If the voltage display indicates LO or HI there may be trouble ...

Page 27: ...h to 4 When released the switch returns to the center position To cancel the turn signal lights push the switch in after it has returned to the center position EAU00129 Horn switch Hornswitch Press this switch to sound the horn EAU00118 Handlebar switches Handlebarswitches EAU00120 Pass switch PASS Passswitch Press this switch to flash the head light EAU03888 Dimmer switch Dimmerswitch Set this sw...

Page 28: ... switch 2 Start switch EAU03801 Start switch Startswitch With the sidestand up push this switch while applying the front or rear brake to crank the engine with the starter EC000005 cC See page 5 1 for starting instruc tions prior to starting the engine EAU03882 Front brake lever Brakelever front The front brake lever is located on the right handlebar grip To apply the front brake pull this lever t...

Page 29: ...TIONS 3 EAU00163 Rear brake lever Brakelever rear The rear brake lever is located on the left handlebar grip To apply the rear brake pull this lever toward the han dlebar grip 1 1 Rear brake lever 5SJ 28199 E1 7 11 02 11 03 AM Page 27 ...

Page 30: ...NT AND CONTROL FUNCTIONS 3 EW000020 w 8 8 The ABS performs best on long braking distances 8 8 On certain rough or gravel roads the braking distance may be longer with than with out the ABS Therefore always keep a sufficient distance to the vehicle ahead to match the riding speed NOTE 8 When the ABS is activated the brakes are operated in the usual way A pulsating action may be felt at the brake le...

Page 31: ...brake hose 3 ABS warning light 4 Fail safe relay 5 ECU Electronic Control Unit 6 Stop relay 7 Hydraulic Unit HU 8 Front brake hose 9 Front wheel sensor rotor 10 Front wheel sensor 11 Fuse boxes 12 ABS test coupler 13 Rear brake hose 14 Rear wheel sensor rotor 15 Rear wheel sensor 5SJ 28199 E1 7 11 02 11 03 AM Page 29 ...

Page 32: ...k will be released and the fuel tank cap can be removed 1 1 Fuel tank cap To install the fuel tank cap 1 Align the match marks insert the fuel tank cap into the tank open ing and then push down on the cap 2 Turn the key counterclockwise to the original position and then remove it 3 Close the lid EWA00028 w Be sure that the fuel tank cap is properly installed and locked before riding the scooter 1 ...

Page 33: ... on the hot engine 1 2 1 Filler tube 2 Fuel level EAU04284 ECA00104 cC Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and pis ton rings as well as to the exhaust system EAU00185 cC Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted sur faces or plastic parts Recommended fuel RE...

Page 34: ...s equipped with a cat alytic converter in the muffler EW000128 w The exhaust system is hot after operation Make sure that the exhaust system has cooled down before doing any maintenance work EC000114 cC The following precautions must be observed to prevent a fire hazard or other damages 8 8 Use only unleaded gasoline The use of leaded gasoline will cause unrepairable damage to the catalytic conver...

Page 35: ...PUSH a a Open EAU03096 Adjusting the rider seat Riderseat adjusting The rider seat can be adjusted as fol lows to change the riding position 1 Open the rider seat 1 1 Rider seat 3 Fold the rider seat up To close the rider seat 1 Fold the rider seat down and then push it down to lock it in place 2 Remove the key from the main switch if the scooter will be left unattended NOTE Make sure that the sea...

Page 36: ...t A To open the storage compartment when it is locked insert the key in the lock turn it counterclockwise and then grasp the lock while pushing the button in To open the storage compartment when it is unlocked simply grasp the lock while pushing the button in 1 2 a 1 Button 2 Lid a Open To lock the storage compartment push the lid into the original position insert the key in the lock turn it clock...

Page 37: ... Do not leave the rider seat open for an extended period of time otherwise the light may cause the battery to discharge EWA00035 w Do not exceed the following load ing limits 8 8 Front storage compartment A 2 kg 8 8 Rear storage compartment 5 kg 8 8 Maximum load for the vehicle 178 kg Rear storage compartment Two helmets can be stored in the storage compartment under the seats See page 3 18 for ri...

Page 38: ...To increase the spring preload and thereby harden the suspension turn the adjusting ring on each shock absorber assembly in direction a To decrease the spring preload and thereby soften the suspension turn the adjusting ring on each shock absorber assembly in direction b a b 1 2 3 1 Spring preload adjusting ring 2 Position indicator 3 Spring preload adjusting tool NOTE 8 Align the appropriate notc...

Page 39: ...vents starting when either brake is applied but the side stand is still down 8 It cuts the running engine when the sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure EW000045 w If a malfunction is noted have a Yamaha dealer check the system before riding EW000044 w The scooter must not be ridden with the sidestand do...

Page 40: ...switch may be defective The scooter should not be ridden until checked by a Yamaha dealer With the engine still off 6 Move the sidestand up 7 Keep the front or rear brake applied 8 Push the start switch Does the engine start With the engine still running 9 Move the sidestand down Does the engine stall The sidestand switch may be defective The scooter should not be ridden until checked by a Yamaha ...

Page 41: ...PRE OPERATION CHECKS Pre operation check list 4 1 4 5SJ 28199 E1 7 11 02 11 03 AM Page 39 ...

Page 42: ... Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 3 5 3 16 3 17 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 14 6 17 Final transmission oil Check vehicle for oil leakage 6 18 6 19 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling syst...

Page 43: ... condition and tread depth Check air pressure Correct if necessary 6 24 6 27 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 3 11 3 12 6 27 6 31 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 31 6 32 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instrument...

Page 44: ...h an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved EWA00033 w If any item in the Pre operation check list is not working properly have it inspected and repaired before operat ing the scooter 5SJ 28199 E1 7 11 02 11 03 AM Page 42 ...

Page 45: ...ORTANT RIDING POINTS Starting the engine 5 1 Starting off 5 2 Acceleration and deceleration 5 3 Braking 5 3 Tips for reducing fuel consumption 5 4 Engine break in 5 4 Parking 5 5 5 5SJ 28199 E1 7 11 02 11 03 AM Page 43 ...

Page 46: ...e with the centerstand down EAU03616 Starting the engine Startingtheengine EC000046 cC See page 5 4 for engine break in instructions prior to operating the vehicle for the first time In order for the ignition circuit cut off system to enable starting the side stand must be up EW000054 w 8 8 Before starting the engine check the function of the igni tion circuit cut off system according to the proce...

Page 47: ...t start try with the throttle open 1 8 turn ECA00045 cC For maximum engine life never accelerate hard when the engine is cold EAU00433 Starting off Startingoff NOTE Before starting off allow the engine to warm up 1 While pulling the rear brake lever with your left hand and holding the grab bar with your right hand push the scooter off the center stand 2 Sit astride the seat and then adjust the rea...

Page 48: ...akes simultaneously while gradually increasing the pressure EW000057 w 8 8 Avoid braking hard or sudden ly especially when leaning over to one side otherwise the scooter may skid or over turn 8 8 Railroad crossings streetcar rails iron plates on road con struction sites and manhole covers become extremely slip pery when wet Therefore slow down when approaching such areas and cross them with cautio...

Page 49: ...ad the fol lowing material carefully Since the engine is brand new do not put an excessive load on it for the first 1 600 km The various parts in the engine wear and polish them selves to the correct operating clear ances During this period prolonged full throttle operation or any condition that might result in engine overheat ing must be avoided EAU04590 0 1 000 km Avoid prolonged operation above...

Page 50: ...8 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them 8 8 Do not park on a slope or on soft ground otherwise the scooter may overturn EC000062 cC Never park in an area where there are fire hazards such as grass or other flammable materials 5SJ 28199 E1 7 11 02 11 03 AM Page 48 ...

Page 51: ...hecking the brake fluid level 6 29 Changing the brake fluid 6 30 Checking and lubricating the cables 6 30 Checking and lubricating the throttle grip and cable 6 31 Lubricating the front and rear brake levers 6 31 Checking and lubricating the centerstand and sidestand 6 31 Checking the front fork 6 32 Checking the steering 6 33 Checking the wheel bearings 6 33 Removing the battery cover 6 34 Batter...

Page 52: ...ERRAIN GEOGRAPHICAL LOCATION AND INDIVIDUAL USE THE MAINTE NANCE INTERVALS MAY NEED TO BE SHORTENED EAU03623 Owner s tool kit Toolkit The owner s tool kit is located inside the rear storage compartment See page 3 20 for the rear storage com partment opening procedures EW000060 w If you are not familiar with scooter maintenance work have a Yamaha dealer do it for you EAU00466 w This scooter is desi...

Page 53: ...epairs However additional tools such as a torque wrench may be nec essary to perform certain mainte nance work correctly 2 1 1 Mat 2 Owner s tool kit NOTE If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you EW000063 w Modifications not approved by Yamaha may cause loss of perfor mance and render the vehicle unsafe for use Consult a Yama...

Page 54: ...ical skills NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1 000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses and vacuum hose for cracks or damage 2 Spark plug Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust 4 Air filter element Clean Replace 5 V belt case air filter element Clean 6 Front brake Check operation fluid level and vehicle for fluid leakage...

Page 55: ...s Make sure that all nuts bolts and screws are properly tightened 14 Sidestand centerstand Check operation Lubricate 15 Sidestand switch Check operation 16 Front fork Check operation and for oil leakage 17 Shock absorber assemblies Check operation and shock absorbers for oil leakage 18 Carburetor Adjust engine idling speed 19 Engine oil Change See page 3 3 and 6 17 for more information about the o...

Page 56: ...oil strainer Clean 21 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 22 Final transmission oil Check vehicle for oil leakage Change 23 V belt Replace Every 20 000 km 24 Front and rear brake switches Check operation 25 Moving parts and cables Lubricate 26 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if nec...

Page 57: ...nel removingandinstalling The cowlings and panel shown above need to be removed to perform some of the maintenance jobs described in this chapter Refer to this section each time a cowling or the panel needs to be removed and installed 1 1 Cowling A 1 1 Cowling C 1 1 Cowling B 5SJ 28199 E1 7 11 02 11 03 AM Page 55 ...

Page 58: ...INOR REPAIR 6 1 1 Panel A 2 Remove the cowling screws 2 1 1 1 Screw 4 2 Cowling A EAU03615 Cowling A Cowling To remove the cowling 1 Pull up the left floorboard mats as shown 1 2 1 Mat A 2 Mat B 5SJ 28199 E1 7 11 02 11 03 AM Page 56 ...

Page 59: ...ll up the right floorboard mats as shown 1 2 1 Mat A 2 Mat B To install the cowling 1 Insert the tabs on the cowling into the slots as shown and then install the screws 2 Place the floorboard mats in the original position ECA00067 cC Take care not to damage the tabs on the cowling when removing and or installing it 1 1 Tab 10 5SJ 28199 E1 7 11 02 11 03 AM Page 57 ...

Page 60: ...s on the cowling into the slots as shown and then install the screws 2 Place the floorboard mats in the original position ECA00067 cC Take care not to damage the tabs on the cowling when removing and or installing it 1 1 Tab 10 3 Pull the cowling down slightly and then pull it outward as shown 5SJ 28199 E1 7 11 02 11 03 AM Page 58 ...

Page 61: ...To remove the cowling 1 Remove the cowling screws 1 1 Screw 2 2 Push the cowling in lightly and then pull it back as shown ECA00067 cC Take care not to damage the tabs on the cowling when removing and or installing it a a a Push 5SJ 28199 E1 7 11 02 11 03 AM Page 59 ...

Page 62: ...cowling into the slots as shown and then push the cowling in until it snaps into place 2 Install the cowling screws 1 2 1 Tab 4 2 Slot 4 EAU03628 Panel A Panel To remove the panel Remove the bolts and then pull the panel out as shown 1 2 1 Bolt 2 2 Panel A 5SJ 28199 E1 7 11 02 11 03 AM Page 60 ...

Page 63: ...e the spark plug cap 1 1 Spark plug cap EAU03620 Checking the spark plug Sparkplug checking The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart In addition the condition of the spark plug can reveal the c...

Page 64: ...rk plug wrench and then tighten it to the specified torque a a Spark plug gap To check the spark plug 1 Check that the porcelain insula tor around the center electrode of the spark plug is a medium to light tan the ideal color when the scooter is ridden normally NOTE If the spark plug shows a distinctly different color the engine could be defective Do not attempt to diagnose such problems yourself...

Page 65: ...ter on the center stand NOTE Make sure that the scooter is posi tioned straight up when checking the oil level 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 EAU04611 Engine oil Engineoil The engine oil level should be checked before each ride In addition the oil must be changed at the inter vals specified in the perio...

Page 66: ...m level mark 3 Minimum level mark To change the engine oil 1 Start the engine warm it up for several minutes and then turn it off 2 Place an oil pan under the engine to collect the used oil 3 Remove the engine oil filler cap and the engine oil drain bolt to drain the oil from the crankcase 1 1 Engine oil drain bolt 4 If the engine oil is below the min imum level mark add sufficient oil of the reco...

Page 67: ... off and check for the cause 8 Reset the oil change indicator light according to the following procedure 6 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap ECA00140 cC 8 8 Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERV ING II or higher 8 8 Be sure n...

Page 68: ...er the oil change for the next periodic oil change to be indicated at the correct time To reset the oil change indicator light before the periodic oil change interval has been reached follow the above procedure but note that the indicator light will come on for 1 4 seconds after releasing the reset button otherwise repeat the proce dure 2 Hold the reset button pushed for two to five seconds 3 Rele...

Page 69: ...n under the final transmission case to collect the used oil EWA00062 w 8 8 Make sure that no foreign material enters the final trans mission case 8 8 Make sure that no oil gets on the tire or wheel 1 1 Final transmission oil drain bolt 4 Remove the oil filler cap and drain bolt to drain the oil from the final transmission case 5 Install the final transmission oil drain bolt and then tighten it to ...

Page 70: ... Coolant The coolant reservoir is located under the battery cover See page 6 34 for battery cover removal and installation procedures To check the coolant level 1 Place the scooter on a level sur face and hold it in an upright position NOTE 8 The coolant level must be checked on a cold engine since the level varies with engine tem perature 8 Make sure that the scooter is positioned straight up whe...

Page 71: ...0080 cC 8 8 If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water since it is harmful to the engine 8 8 If water has been used instead of coolant replace it with coolant as soon as possible otherwise the engine may not be sufficiently cooled and the cooling system will not be pro tected against frost and corro sion 8 8 If water has been added...

Page 72: ... be operated without the filter ele ments installed otherwise the piston and or cylinder may become excessively worn 4 Check the sponge material for damage and replace it if neces sary 5 Allow the sponge material to dry 6 Apply oil of the recommended type to the entire surface of the sponge material and then squeeze the excess oil out Cleaning the air filter element 1 Place the scooter on the cent...

Page 73: ...stall the V belt case air filter element cover by installing the screws 7 Install the air filter case cover by installing the screws 8 Install the cowling 2 1 1 V belt case air filter cover 2 V belt case air filter element Cleaning the V belt case air filter element 1 Remove cowling A See page 6 7 for cowling removal and installation procedures 2 Remove the air filter case cover by removing the sc...

Page 74: ... the valve clearance Valveclearance adjusting The valve clearance changes with use resulting in improper air fuel mix ture and or engine noise To prevent this from occurring the valve clear ance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart EAU00635 Adjusting the throttle cable free play Throttlecablefreeplay adjusting The throttle...

Page 75: ...75 kPa 1 75 kgf cm2 1 75 bar 200 kPa 2 00 kgf cm2 2 00 bar 90 kg load maximum 200 kPa 2 00 kgf cm2 2 00 bar 225 kPa 2 25 kgf cm2 2 25 bar EW000082 w 8 8 The tire air pressure must be checked and adjusted on cold tires i e when the tempera ture of the tires equals the ambient temperature 8 8 The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of ride...

Page 76: ...not carry along loosely packed items which can shift during a ride 8 8 Securely pack the heaviest items close to the center of the scooter and distribute the weight evenly on both sides Tire inspection The tires must be checked before each ride If the center tread depth reaches the specified limit if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer re...

Page 77: ...eel must be replaced 8 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 handling characteristics and a shortened tire life EAU00683 w 8 8 Have a Yamaha dealer replace excessively worn tires Besides being illegal operat ing the scooter with exces sively worn tires decreases riding stability and can...

Page 78: ...tion b 3 Tighten the locknut EW000101 w If proper adjustment cannot be obtained as described have a Yamaha dealer make this adjust ment 1 c a b 2 1 Locknut 2 Adjusting bolt c Brake lever free play EAU00703 Adjusting the front and rear brake lever free play Frontandrearbrakeleverfreeplay adjusting The front and rear brake lever free play should measure 2 5 mm as shown Periodically check the front a...

Page 79: ...e pads Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear without having to disassemble the brake Check the brake pad wear as follows 1 Remove the brake caliper bolt and then tilt the caliper forward to inspect the wear indicator groove If a brake pad has worn to the point that the wear indica tor groove has almost disap peared have a Yamaha ...

Page 80: ... reservoir is level 8 Use only the recommended qual ity brake fluid otherwise the rub ber seals may deteriorate caus ing leakage and poor braking performance 1 1 Minimum level mark EAU04904 Checking the brake fluid level Brakefluidlevel checking Insufficient brake fluid may allow air to enter the brake system possibly causing it to become ineffective Before riding check that the brake fluid is abo...

Page 81: ...ing The operation of all control cables and the condition of the cables should be checked before each ride and the cables and cable ends should be lubricated if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it EW000112 w Damage to the outer sheath may interfere with proper cable opera tion and will cause the inner cable to rust Replace a damaged ca...

Page 82: ...ubricating The operation of the centerstand and sidestand should be checked before each ride and the pivots and metal to metal contact surfaces should be lubricated if necessary EW000114 w If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or repair it EAU03118 Lubricating the front and rear brake levers Brakelevers lubricating The pivoting points of the ...

Page 83: ...rate smoothly have a Yamaha dealer check or repair it EAU02939 Checking the front fork Frontfork checking The condition and operation of the front fork must be checked as follows at the intervals specified in the peri odic maintenance and lubrication chart To check the condition EW000115 w Securely support the scooter so that there is no danger of it falling over Check the inner tubes for scratche...

Page 84: ...ely support the scooter so that there is no danger of it falling over EAU01144 Checking the wheel bearings Wheelbearings checking The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings 2 Hold the lower ends of...

Page 85: ...ere is no need to check the electrolyte or to add distilled water To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged Keep in mind that the battery tends to dis charge more quickly if the scooter is equipped with optional electrical accessories 1 1 Battery To remove the battery cover pull up the right footboard mat as shown and then remo...

Page 86: ... water for 15 minutes and seek prompt medical attention To store the battery 1 If the scooter will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place 2 If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before installation 8 8 Batteries produce ex...

Page 87: ...e a fuse of a higher amperage rating than recommend ed to avoid causing extensive damage to the electrical system and possibly a fire EAU04110 Replacing the fuses Fuses replacing The fuse boxes are located under the battery cover See page 6 34 for bat tery cover removal and installation procedures If a fuse is blown replace it as fol lows 4 5 7 9 6 1 8 3 2 9 10 1 Main fuse 2 Backup fuse clock 3 AB...

Page 88: ...stem 3 Disconnect the headlight cou pler and then remove the bulb cover 1 2 1 Headlight coupler 2 Bulb cover EAU04128 Replacing a headlight bulb Headlightbulb replacing This scooter is equipped with quartz bulb headlights If a headlight bulb burns out replace it as follows 1 Place the scooter on the center stand 2 Remove panel A See page 6 11 for panel removal and installation procedures 5SJ 28199...

Page 89: ...uch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner 6 Install the headlight bulb cover and then connect the coupler a a Do not touch the glass part of the bu...

Page 90: ...n and turning it coun terclockwise 5 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 6 Install the socket together with the bulb by turning it clockwise 7 Install the panel 1 1 Socket EAU03111 Replacing a front turn signal light bulb Turnsignallightbulb front replacing 1 Place the scooter on the center stand 2 Remove panel A See page 6 11 for panel removal a...

Page 91: ...a tail brake light bulb Tail brakelightbulb replacing 1 Place the scooter on the center stand 2 Remove cowling C See page 6 10 for cowling removal and installation procedures 3 Remove the socket together with the bulb by turning it coun terclockwise 4 Remove the defective bulb by pulling it out 5 Insert a new bulb into the socket 6 Install the socket together with the bulb by turning it clockwise ...

Page 92: ...ock wise until it stops 6 Install the socket together with the bulb by turning it clockwise 7 Install the cowling 1 1 Socket 3 Remove the license plate light lens by removing the screws 1 2 1 License plate light lens 2 Screw 2 EAU03621 Replacing the license plate light bulb Licenseplatelightbulb replacing 1 Place the scooter on the center stand 2 Remove cowling C See page 6 10 for cowling removal ...

Page 93: ...ation Any problem in the fuel compression or ignition sys tems for example can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your scooter require any repair take it to a Yamaha dealer whose skilled techni cians have the necessary tools experience and know how to service the sc...

Page 94: ...on There is no compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric start...

Page 95: ...When the hissing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap NOTE 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 The coolant level is OK The coolant level is low...

Page 96: ...5SJ 28199 E1 7 11 02 11 03 AM Page 94 ...

Page 97: ...SCOOTER CARE AND STORAGE Care 7 1 Storage 7 4 7 5SJ 28199 E1 7 11 02 11 03 AM Page 95 ...

Page 98: ... well as all electrical cou plers and connectors including the spark plug cap are tightly installed 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such products onto seals gaskets and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00011 cC 8 8 Avoid using strong acidic wheel cleaners especially on s...

Page 99: ... leave any marks If the windshield is scratched use a quality plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottle brush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes b...

Page 100: ...ax all painted surfaces 7 Let the scooter dry completely before storing or covering it EWA00002 w 8 8 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 regular brake disc cleaner or acetone and wash the tires with warm water and a mild detergent 8 8 Before operating the scooter test its braking performance and cornering behavio...

Page 101: ...our the drained fuel into the fuel tank 3 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 4 Perform the following steps to protect the cylinder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap onto the sp...

Page 102: ...ttle every month in order to pre vent the tires from becoming degraded in one spot 7 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 8 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an excessively cold or warm place less than 0 C or more than 30 C For more informa tion on storing the batter...

Page 103: ...SPECIFICATIONS Specifications 8 1 Conversion table 8 5 8 5SJ 28199 E1 7 11 02 11 03 AM Page 101 ...

Page 104: ...single cylinder Displacement 249 cm3 Bore Stroke 69 0 66 8 mm Compression ratio 10 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher cC Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Q...

Page 105: ...uction system Helical gear Primary reduction ratio 40 15 2 666 Secondary reduction system Helical gear Secondary reduction ratio 38 15 2 533 Transmission type V belt automatic Operation Centrifugal automatic type Chassis Frame type Steel tube underbone Caster angle 28 Trail 103 mm Tires Front Type Tubeless Size 110 90 12 64L Manufacturer IRC MB67 model MICHELIN BOPPER Rear Type Tubeless Size 130 7...

Page 106: ...t hand Fluid DOT 4 Rear Type Single disc brake Operation Left hand Fluid DOT 4 Suspension Front Telescopic fork Rear Unit swing Spring shock absorbers Front Coil spring oil damper Rear Coil spring oil damper Wheel travel Front 100 mm Rear 90 mm Electrical Ignition system Transistorized coil ignition digital Charging system Type A C magneto Standard output 14 V 19 5 A 5 000 r min Battery Type GT7B ...

Page 107: ...se plate light 12 V 5 W 1 Meter lighting 12 V 1 7 W 4 High beam indicator light 12 V 1 7 W 1 Turn signal indicator light 12 V 3 4 W 2 Oil change indicator light 12 V 1 7 W 1 ABS warning light 12 V 1 7 W 1 Fuses Main fuse 30 A ABS motor fuse 30 A Headlight fuse 15 A Signaling system fuse 15 A ABS control unit fuse 10 A Ignition fuse 7 5 A Radiator fan fuse 4 A Clock Backup fuse 10 A 5SJ 28199 E1 7 ...

Page 108: ...TEM TO IMPERIAL SYSTEM Metric unit Conversion factor Imperial unit Torque m kgf m kgf cm kgf cm kgf 7 233 86 794 0 0723 0 8679 ft lbf in lbf ft lbf in lbf Weight kg g 2 205 0 03527 lb oz Speed km h 0 6214 mi h Distance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm3 cc cm3 L liter L liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Mis...

Page 109: ...CONSUMER INFORMATION Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 9 5SJ 28199 E1 7 11 02 11 03 AM Page 107 ...

Page 110: ...MATION EAU01041 Key identification number Keyidentificationnumber The key identification number is stamped into the key tag Record this number in the space pro vided and use it for reference when ordering a new key EAU01044 Vehicle identification number Vehicleidentificationnumber The vehicle identification number is stamped into the frame NOTE The vehicle identification number is used to identify...

Page 111: ...of the rear storage compart ment See page 3 20 for rear stor age compartment opening and clos ing procedures Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 1 Model label 5SJ 28199 E1 7 11 02 11 03 AM Page 109 ...

Page 112: ...ghts 3 2 K Key identification number 9 1 L License plate light bulb replacing 6 41 M Main switch steering lock 3 1 Model label 9 2 P Parking 5 5 Part locations 2 1 Periodic maintenance and lubrication chart 6 3 Pre operation check list 4 1 R Rider seat 3 18 Rider seat adjusting 3 18 A ABS 3 13 Acceleration and deceleration 5 3 Air filter and V belt case air filter elements cleaning 6 21 Air flow l...

Page 113: ...ter 3 4 Tail brake light bulb replacing 6 40 Throttle cable free play adjusting 6 23 Throttle grip and cable checking and lubricating 6 31 Tires 6 24 Tool kit 6 1 Troubleshooting 6 42 Troubleshooting charts 6 43 Turn signal light bulb front replacing 6 39 Turn signal light bulb rear replacing 6 40 V Valve clearance adjusting 6 23 Vehicle identification number 9 1 W Wheel bearings checking 6 33 Whe...

Page 114: ...5SJ 28199 E1 7 11 02 11 03 AM Page 112 ...

Page 115: ...5SJ 28199 E1 7 11 02 11 03 AM Page 112 ...

Page 116: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2002 8 0 1 1 YAMAHA MOTOR CO LTD E ...

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