Yamaha VERSITY 300 VP300 Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-18

6

WARNING

EWA11200

Because loading has an enormous
impact on the handling, braking,
performance and safety characteris-
tics of your vehicle, you should keep
the following precautions in mind.

●

NEVER OVERLOAD THE VEHI-
CLE! Operation of an overload-
ed vehicle may result in tire
damage, loss of control, or se-
vere injury. Make sure that the
total weight of rider, passenger,
cargo, and accessories does
not exceed the specified maxi-
mum load for the vehicle.

●

Do not carry along loosely
packed items, which can shift
during a ride.

●

Securely pack the heaviest
items close to the center of the
vehicle and distribute the
weight evenly on both sides.

●

Adjust the tire air pressure with
regard to the load.

●

Check the tire condition and air
pressure before each ride.

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-
place the tire immediately.

NOTE:

The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.

Tire information

This model is equipped with tubeless
tires.

WARNING

EWA10470

●

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.

●

The replacement of all wheel
and brake related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.

1. Tire tread depth

2. Tire sidewall

Minimum tire tread depth (front and
rear):

1.6 mm (0.06 in)

1

2

ZAUM0054

Front tire:

Size:

120/80-14 58P

Manufacturer/model:

MICHELIN/PILOT CITY TL

Rear tire:

Size:

150/70-14 66P

Manufacturer/model:

MICHELIN/PILOT CITY TL

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Summary of Contents for VERSITY 300 VP300

Page 1: ...OWNER S MANUAL VP300 1S6 F8199 E1 ...

Page 2: ......

Page 3: ...this manual thoroughly so as to enjoy all advantages of your VP300 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 condition If you have any fur ther questions do not hesitate to co...

Page 4: ... be minor discrepancies between your scooter and this manual If you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA12410 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS SCOOTER The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to th...

Page 5: ...TION EAUM1010 VP300 OWNER S MANUAL 2004 by MBK INDUSTRIE 1st edition August 2004 All rights reserved Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly prohibited Printed in France ...

Page 6: ...deceleration 5 2 Braking 5 2 Tips for reducing fuel consumption 5 3 Engine break in 5 3 Parking 5 4 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 Owner s tool kit 6 1 Periodic maintenance and lubrication chart 6 2 Removing and installing cowlings and panels 6 5 Checking the spark plug 6 9 Engine oil 6 10 Final transmission oil 6 12 Coolant 6 13 Air filter and V belt case air filter elements 6 14 Adjus...

Page 7: ...b or a rear turn signal light bulb 6 29 Replacing the license plate light bulb 6 30 Troubleshooting 6 30 Troubleshooting charts 6 31 SCOOTER CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 ...

Page 8: ...he scooter Making yourself con spicuous appears to be very effec tive in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when ap proaching and passing through intersections since intersec tions are the most likely places for scooter accidents to occur Ride where other motorists can see you Avoid riding in another motorist s blind spot Many ac...

Page 9: ...shoes trousers gloves etc is ef fective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers or wheels and cause injury or an accident Never touch the engine or exhaust system during or after operation They become very hot and can cause burns Always wear protec tive clothing that covers your legs ankles and feet Passen...

Page 10: ...reduce ground clearance or cornering clearance limit sus pension travel steering travel or control operation or obscure lights or reflectors Accessories fitted to the handle bar or the front fork area can create instability due to improper weight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be k...

Page 11: ... line inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediately If any gasoline spills on your skin or clothing immediately wash the affected area with soap and water and change your clothes EAU10371 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 ...

Page 12: ...RMATION 1 5 1 Always wear a helmet gloves trousers tapered around the cuff and ankle so they do not flap and a bright colored jacket Do not carry too much luggage on the scooter An overloaded scoot er is unstable ...

Page 13: ...3 2 1 Rear storage compartment page 3 13 2 Shock absorber assembly spring preload adjusting ring page 3 14 3 Air filter element page 6 14 4 V belt case air filter element page 6 14 5 Sidestand page 3 15 6 23 6 Coolant level check window page 6 13 ...

Page 14: ... 5 2 3 4 1 Grab bar page 5 2 2 Fuel tank cap page 3 9 3 Battery page 6 25 4 Coolant reservoir cap page 6 13 5 Front brake pads page 6 20 6 Main fuse box page 6 26 7 Engine oil filler cap page 6 10 8 Centerstand page 6 23 9 Rear brake pads page 6 20 ...

Page 15: ...ebar switches page 3 7 3 Front storage compartment B page 3 12 4 Speedometer Multi function display page 3 2 3 4 5 Luggage hook page 3 14 6 Main switch steering lock page 3 1 7 Right handlebar switches page 3 7 8 Throttle grip page 6 16 9 Front brake lever page 3 8 10 Front storage compartment A page 3 12 11 Fuse box page 6 26 ...

Page 16: ... turned to or the sid estand is moved down EAU10660 OFF All electrical systems are off The key can be removed EAU10680 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the posi tion and then turn it to while still pushing it 3 Remove the key To unlock the steering Push th...

Page 17: ...indicator light comes on when the high beam of the headlight is switched on EAUM1050 Low beam indicator light This indicator light comes on when the low beam of the headlight is switched on EAU11590 Speedometer UK ONLY The speedometer shows the riding speed 1 Low beam indicator light 2 Left turn signal indicator light 3 Right turn signal indicator light 4 High beam indicator light 1 2 3 4 ZAUM0578...

Page 18: ...ble NOTE Do not allow the fuel tank to empty itself completely EAUM1101 Battery voltage coolant temperature gauge When the key is turned to this gauge indicates the battery voltage lev el before the engine was stopped NOTE If the needle drops to the 9V low mark have a Yamaha dealer check the battery When the key is turned to this gauge indicates the coolant tempera ture If the needle reaches the r...

Page 19: ... reading is displayed in F For other countries the distance traveled is displayed in kilometers and the temperature reading is dis played in C Odometer and tripmeter modes Pushing the MODE button switches the display between the odometer mode Total and the tripmeter modes Trip in the following order Total Trip 1 Trip 2 Trip fuel Total NOTE The Trip fuel odometer is only acti vated if the fuel leve...

Page 20: ...n for at least one sec ond If you do not reset the fuel reserve tripmeter manually it will reset itself au tomatically and the display will return to the prior mode after refueling and trav eling 5 km 3 mi Clock mode To set the clock 1 When the display is in the Total mode push the SET button for at least two seconds 2 When the hour digits start flashing push the SET button to set the hours 3 Push...

Page 21: ...lding the MODE and SET buttons pushed for two to five seconds 3 Release the buttons and the oil change indicator will go off NOTE The oil change indicator will come on at the initial 1000 km 600 mi and every 3000 km 4800 mi thereafter 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 in dicator must be reset after...

Page 22: ...s switch to flash the headlight EAU12400 Dimmer switch Set this switch to for the high beam and to for the low beam EAU12460 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When re leased the switch returns to the center 1 Alarm indicator light 1 ZAUM0406 1 Pass switch 2 Dimmer switch 3 Turn signal switch 4 Horn switch 1 2 3 4 ZAUM0...

Page 23: ...osition set this switch to to turn on the hazard lighting simultaneous flashing of all turn signal lights To turn off the hazard lighting set this switch to and then turn the key to NOTE Even if the key is turned from to with the hazard lighting on the hazard lighting will continue to flash re gardless of the hazard switch position To cancel the hazard lighting the key must be turned to and the ha...

Page 24: ...and the fuel tank cap can be removed To install the fuel tank cap 1 Insert the fuel tank cap into the tank opening with the marks on the cap and tank aligned 2 Turn the key counterclockwise to the original position and then re move it 3 Close the seat NOTE The fuel tank cap cannot be installed unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed ...

Page 25: ...N ECA11400 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging oc curs use a gasoline of a different brand or premium unleaded fuel Use of...

Page 26: ...unrepairable damage to the catalytic converter Never park the vehicle near pos sible fire hazards such as grass or other materials that easily burn Do not allow the engine to idle too long EAU13931 Seat To open the seat 1 Place the scooter on the center stand 2 Insert the key into the main switch and then turn it counterclockwise NOTE Do not push inward when turning the key 3 Fold the seat up To c...

Page 27: ...he lock and turn it 1 4 turn counterclockwise and then re move the key WARNING EWA10960 Do not exceed the load limit of 1 kg 2 2 lb for the storage com partment Do not exceed the maximum load of 202 kg 445 lb for the ve hicle EAUM1490 Storage compartment To open the storage compartment Push on the mark of the storage compartment lid To close the storage compartment Push the lid into the original p...

Page 28: ...while the scooter is being washed wrap any articles stored in the compartment in a plastic bag Do not keep anything valuable or breakable in the storage com partment To store a helmet in the storage com partment place the helmet with the front facing backward NOTE Some helmets cannot be stored in the storage compartment because of their size or shape Do not leave your scooter unat tended with the ...

Page 29: ... 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 NOTE Align the appropriate notch in the ad justing ring with the position indicator on the shock absorber EAUT1070 Luggage hook WARNING EWAT1030 Do not exceed the loa...

Page 30: ... 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 as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU15371 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch and brake light switches h...

Page 31: ...art switch Does the engine start With the engine still running 9 Move the sidestand down Does the engine stall The system is OK The scooter can be ridden This check is most reliable if performed with a warmed up engine The sidestand switch may be defective The scooter should not be ridden until checked by a Yamaha dealer The brake switch may be defective The scooter should not be ridden until chec...

Page 32: ...nnected to the auxiliary DC terminals should not be used with the engine turned off and their combined load must never ex ceed 2 5 A or 30 W otherwise the battery may discharge To use the auxiliary DC jack 1 Turn the key to 2 Remove the dust cap from the re ceptacle 3 Insert the accessory plug into the receptacle 4 Turn the key to and then start the engine See page 5 1 5 When the accessory jack is...

Page 33: ...e could have serious consequences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre ope...

Page 34: ...peration If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 19 6 20 6 20 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check flu...

Page 35: ...necessary 6 22 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 23 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 defective have Yamaha dealer che...

Page 36: ... circuit cut off system to enable starting the side stand must be up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 15 Never ride with the sidestand down 1 Turn the key to and make sure that the engine stop switch is set to 2 Close the throttle completely 3 Start the engine by pushing the start ...

Page 37: ...ation The speed can be adjusted by opening and closing the throttle To increase the speed turn the throttle grip in direction a To reduce the speed turn the throt tle grip in direction b EAU16791 Braking 1 Close the throttle completely 2 Apply both front and rear brakes simultaneously while gradually in creasing the pressure WARNING EWA10300 Avoid braking hard or suddenly especially when leaning o...

Page 38: ...ffic jams at traffic lights or at railroad crossings EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish t...

Page 39: ...e break in period immediately have a Yamaha dealer check the vehicle EAU17212 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10310 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 Do not park on a slope or on soft ground otherwise the vehicle may overturn CAUTION ECA1038...

Page 40: ...aved roads only If this scooter is operated in abnormally dusty mud dy or wet conditions the air filter el ement should be cleaned or replaced more frequently otherwise rapid engine wear may result Con sult a Yamaha dealer for proper maintenance intervals EAUT1120 Owner s tool kit The owner s tool kit is located inside the front storage compartment See page 3 12 The service information included in...

Page 41: ...O ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel and vacuum hoses 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 ele ment Clean 6 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pad...

Page 42: ...d centerstand Check operation Lubricate 15 Sidestand switch Check operation 16 Front fork Check operation and for oil leakage 17 Shock absorber assem blies Check operation and shock absorbers for oil leakage 18 Carburetor Adjust engine idling speed 19 Engine oil Change See page 3 4 When the oil change indicator comes on every 3000 km Check oil level and vehicle for oil leakage Every 3000 km 20 Eng...

Page 43: ... brake hoses every four years and if cracked or damaged 23 V belt Replace Every 20000 km 24 Front and rear brake switches Check operation 25 Moving parts and ca bles Lubricate 26 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 27 Lights signals and switches Check operation Adjust headlight ...

Page 44: ...and panels shown need to be removed to perform some of the maintenance jobs described in this chapter Refer to this section each time a cowling or panel needs to be re moved and installed 1 Cowling A 1 ZAUM0421 1 Cowling B 1 Windshield 2 Panel A 1 ZAUM0422 1 2 ZAUM0420 1 Panel B 1 Panel C 1 ZAUM0424 1 ZAUM0425 ...

Page 45: ... cowling 1 Connect the headlight coupler and the turn signal coupler 2 Place the cowling in the original position and then install the screws 3 Install the panel 4 Place the floorboard mats in their original position EAUM1520 Cowling B To remove the cowling 1 Pull up the floorboard mat on each side of the scooter 1 Panel D 1 Panel E 1 ZAUM0426 1 ZAUM0584 1 Cowling A 2 Screw 3 Floorboard mat 1 Turn...

Page 46: ...nel 1 Remove the screws and then take the windshield off 2 Remove the screws and then pull the panel out as shown To install the panel 1 Place the panel in the original posi tion and then install the screws 2 Place the windshield in the original position and then install the screws EAU19280 Panel B To remove the panel Remove the screw and then pull the panel off as shown 1 Screw 2 Cowling B 1 Scre...

Page 47: ...To install the panel 1 Place the panel in the original posi tion 2 Place the floorboard mat in the original position EAU19501 Panel D To remove the panel Pull the panel off as shown To install the panel Place the panel in the original position EAU19280 Panel E To remove the panel Remove the screw and then pull the panel off as shown 1 Screw 2 Panel B 1 2 ZAUM0434 1 Floorboard mat 1 Panel C 1 ZAUM0...

Page 48: ...al the condition of the engine To remove the spark plug 1 Remove cowling B See page 6 6 2 Remove the spark plug cap 3 Remove the spark plug as shown with the spark plug wrench includ ed in the owner s tool kit To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medium to light tan the ideal color when the vehicle is ridden normally NOTE I...

Page 49: ...ble 4 Install the spark plug cap 5 Install the cowling EAUM1550 Engine oil The engine oil level should be checked before each ride In addition the oil must be changed at the intervals spec ified in the periodic maintenance and lubrication chart and when the service indicator light comes on To check the engine oil level 1 Place the scooter on the center stand NOTE Make sure that the scooter is posi...

Page 50: ...washer for damage and replace it if necessary 5 Install the washer and the engine oil drain bolt and then tighten the drain bolt to the specified torque NOTE Make sure that the washer is properly seated 6 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap CAUTION ECA11670 Do not use oils with a diesel specification of CD or oils of a higher quali...

Page 51: ...ition the final transmis sion oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart 1 Start the engine warm it up by riding the scooter for several min utes 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 4 Remove the oil filler cap and drain bolt to d...

Page 52: ...The coolant reservoir is located under the battery cover See page 6 7 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE The coolant level must be checked on a cold engine since the level varies with engine temperature 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 t...

Page 53: ...ing the coolant WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot The coolant must be changed at the in tervals specified in the periodic mainte nance and lubrication chart Have a Yamaha dealer change the coolant EAUM2030 Air filter and V belt case air filter elements The air filter and V belt case air filter el ements should be cleaned at the inter vals specified in...

Page 54: ...sponge material into the air filter case 8 Install the air filter case cover by in stalling the screws Cleaning the V belt case air filter el ement 1 Remove the air filter case cover by removing the screws 2 Remove the V belt case air filter cover by removing the screws 3 Blow the dirt out of the air filter ele ment with compressed air as shown 4 Check the V belt case air filter ele ment for damag...

Page 55: ...he engine and requires very sophisti cated adjustment Therefore all carbu retor adjustments should be left to a Yamaha dealer who has the neces sary professional knowledge and expe rience EAU21381 Checking the throttle cable free play The throttle cable free play should mea sure 1 5 3 0 mm 0 06 0 12 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Ya...

Page 56: ... necessary adjusted before each ride WARNING EWA10500 The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model ZAUM0053 Tire air pressure measured on cold ...

Page 57: ...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 place the tire immediately NOTE The tire tread depth limits may differ from country to country Always comply with the local regulations Tire information This model is equipped with tubeless tires WARNING E...

Page 58: ...result in poor performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics EAUM2060 Checking the front and rear brake lever free play The brake lever free play should mea sure 2 0 5 0 mm 0 08 0 20 in as shown Periodically check the brake le ver f...

Page 59: ...as worn to the point that the wear indicator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU22500 Rear brake pads Check each rear brake pad for damage and measure the lining thickness If a brake pad is damaged or if the lining thickness is less than 3 8 mm 0 15 in have a Yamaha dealer replace the brake pads as a set EAU22580 Checking the brake fluid level Fr...

Page 60: ... Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is n...

Page 61: ...inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23110 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart EAU23170 Lubricating the front and rear brake levers The p...

Page 62: ...ir it EAU23271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 P...

Page 63: ...ing Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front f...

Page 64: ... possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of conta...

Page 65: ...n stallation 4 After installation make sure that the battery leads are properly con nected to the battery terminals CAUTION ECA10630 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant volt age battery charger is required Using a conventional battery charger will damage the battery If you do not have ...

Page 66: ...again have a Yamaha dealer check the electrical system EAU23841 Replacing the headlight bulb This model is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove cowling A together with the headlight unit See page 6 6 2 Disconnect the headlight coupler and then remove the bulb cover 3 Remove the headlight bulb holder by pushing it inward and turning it...

Page 67: ...ts on the headlight bulb using a cloth moistened with al cohol or thinner 5 Install the headlight bulb cover and then connect the coupler 6 Install the cowling together with the headlight unit 7 Have a Yamaha dealer adjust the headlight beam if necessary EAUT1260 Replacing a front turn signal light bulb CAUTION ECA10670 It is advisable to have a Yamaha dealer perform this job 1 Place the scooter o...

Page 68: ...al light bulb 1 Place the scooter on the center stand 2 Remove panel E See page 6 8 3 Remove the socket together with the bulb by turning it counter clockwise 4 Remove the defective bulb by pushing it in and turning it counter clockwise 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 Ins...

Page 69: ...ction before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems 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 re quire any repair take it to a Yamaha dealer whose skilled technician...

Page 70: ...s compression 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 ele...

Page 71: ...ressure to escape 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 co...

Page 72: ...remove dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical produc...

Page 73: ...s to prevent corrosion After cleaning 1 Dry the scooter with a chamois or an absorbing cloth 2 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 3 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal in...

Page 74: ...n the Care section of this chapter 2 Drain the carburetor float chamber by loosening the drain bolt this will prevent fuel deposits from building up Pour 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 pro tect the cylinder piston rings etc from co...

Page 75: ...er so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent 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 ex cessively cold or wa...

Page 76: ...qt 1 06 Imp qt Final transmission oil Type SAE10W30 type SE motor oil Quantity 0 25 L 0 26 US qt 0 22 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 40 L 0 42 US qt 0 35 Imp qt Radiator capacity including all routes 1 60 L 1 69 US qt 1 41 Imp qt Air filter Air filter element Wet element Fuel Recommended fuel Regular unleaded gasoline only Fuel tank capacity 10 9 L ...

Page 77: ...ng condition 160 202 kg 353 445 lb Front 190 kPa 28 psi 1 90 kgf cm Rear 220 kPa 32 psi 2 20 kgf cm Front wheel Wheel type Cast wheel Rim size 14 x MT2 75 Rear wheel Wheel type Cast wheel Rim size 14 x MT4 00 Front brake Type Single disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Left hand operation Recommended fluid DOT 4 Front suspens...

Page 78: ...2 V 10 0 W 2 Auxiliary light 12 V 5 0 W 2 Licence plate light 12 V 5 0 W 1 Meter lighting LED High beam indicator light LED Turn signal indicator light LED Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 15 0 A Ignition fuse 7 5 A Radiator fan fuse 15 0 A Auxiliary DC jack fuse 3 0 A Backup fuse 3 0 A ...

Page 79: ... MODEL LABEL INFORMATION EAU26381 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26410 Vehicle identification number The vehicle identification number is stamped into the frame NOTE The vehicle identification number is used to identify your vehicle and may be used to re...

Page 80: ...del label The model label is affixed to the bottom of the seat See page 3 11 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label 1 ZAUM0469 ...

Page 81: ...s replacing 6 26 H Handlebar switches 3 7 Hazard switch 3 8 Headlight bulb replacing 6 27 High beam indicator light 3 2 Horn switch 3 8 I Identification numbers 9 1 Ignition circuit cut off system 3 15 Indicator lights 3 2 K Key identification number 9 1 L License plate light bulb replacing 6 30 Low beam indicator light 3 2 Luggage hook 3 14 M Main switch steering lock 3 1 Model label 9 2 P Parkin...

Page 82: ...INDEX V Valve clearance 6 17 Vehicle identification number 9 1 W Wheel bearings checking 6 25 Wheels 6 19 ...

Page 83: ......

Page 84: ... E YAMAHA MOTOR CO LTD PRINTED IN FRANCE 2004 09 ...

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