Yamaha Versity 300 Owner'S Manual Download Page 47 | Manualshive

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EAU00462

PERIODIC MAINTENANCE AND MINOR REPAIR

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 ....................................... 6-11
Engine oil .............................................................. 6-13
Final transmission oil ............................................ 6-16
Coolant .................................................................. 6-17
Air filter and the V-belt case air filter elements ...... 6-18
Adjusting the carburetor ........................................ 6-20
Adjusting the throttle cable free play ..................... 6-20
Adjusting the valve clearance ............................... 6-21
Tires ...................................................................... 6-21
Cast wheels .......................................................... 6-23
Adjusting the front and rear brake lever
free play ................................................................ 6-23
Checking the front and rear brake pads ................ 6-24
Checking the brake fluid level ............................... 6-24
Changing the brake fluid ....................................... 6-25

Checking and lubricating the cables ..................... 6-26
Checking and lubricating the throttle grip
and cables ............................................................. 6-26
Lubricating the front and rear brake levers ........... 6-26
Checking and lubricating the centerstand
and sidestand ........................................................ 6-27
Checking the front fork .......................................... 6-27
Checking the steering ........................................... 6-28
Checking the wheel bearings ................................ 6-29
Battery ................................................................... 6-29
Replacing the fuses .............................................. 6-30
Replacing a headlight bulb .................................... 6-32
Replacing a front turn signal light bulb .................. 6-34
Replacing tail/brake light bulb
or rear turn signal light bulb .................................. 6-34
Replacing the license plate light bulb .................... 6-35
Troubleshooting ..................................................... 6-35
Troubleshooting charts .......................................... 6-36

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Summary of Contents for Versity 300

Page 1: ...OWNER S MANUAL VP300 1S6 F8199 E0 ...

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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 further questions do not hesitate to con...

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

Page 5: ...EW000002 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS SCOOTER WARNING IMPORTANT MANUAL INFORMATION ...

Page 6: ...P300 OWNER S MANUAL 2004 by MBK INDUSTRIE 1st Edition January 2004 All rights reserved Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly prohibited Printed in France ...

Page 7: ...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 EAU00009 TABLE OF CONTENTS 2 3 4 5 6 7 8 9 INDEX ...

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Page 9: ...GIVE SAFETY THE RIGHT OF WAY 1 1 EAU00021 EW000015 GIVE SAFETY THE RIGHT OF WAY 1 ...

Page 10: ...influence of 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 passengers Always wear a complete scooter suit whether made of leather or tear resistant synthetic materials with protectors sturdy boots scooter gloves and a properly fitting helmet Optimum protective wear however sh...

Page 11: ...iver might not see you and open a door in your path 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 The brake pads could get wet when you wash the scooter After washing the scooter check the brakes before riding A...

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Page 13: ...EAU00026 DESCRIPTION Left view 2 1 Right view 2 2 Controls and instruments 2 3 2 ...

Page 14: ...1 Rear storage compartment Page 3 13 2 Shock absorber spring preload adjusting ring Page 3 14 3 Air filter element Page 6 18 4 V belt case air filter element page 6 18 5 Sidestand page 3 16 6 27 6 Coolant level check window page 6 17 2 1 ...

Page 15: ...el tank cap Page 3 10 9 Battery Page 6 29 10 Coolant reservoir cap Page 6 17 11 Front brake pads page 6 24 12 Main fuse box page 6 30 13 Engine oil filler cap page 6 13 14 Centerstand page 6 27 15 Rear brake pads page 6 24 7 15 14 13 12 11 8 9 10 2 2 ...

Page 16: ...itches Page 3 8 18 Front storage compartment B Page 3 13 19 Speedometer multi function display page 3 2 20 Luggage hook page 3 15 21 Main switch steering lock page 3 1 22 Right handlebar switches page 3 8 23 Throttle grip page 6 20 6 26 24 Front brake lever page 3 9 6 26 25 Front storage compartment A page 3 12 26 Fuse box page 6 30 2 3 ...

Page 17: ...function display 3 4 Anti theft alarm optional 3 7 Handlebar switches 3 8 Front brake lever 3 9 Rear brake lever 3 9 Fuel tank cap 3 10 Fuel 3 10 Catalytic converter 3 11 Seat 3 12 Storage compartments 3 12 Anti theft device housing 3 14 Adjusting the shock absorber assemblies 3 14 Luggage hook 3 15 Sidestand 3 16 Ignition circuit cut off system 3 16 Auxiliary DC jack 3 18 3 ...

Page 18: ...on and then turn it to lock while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to off while still pushing it EW000016 Never turn the key to or while the scooter is moving otherwise the electrical systems will be switched off which may result in loss of control or an accident Make sure that the scooter is stopped before turning the key to or EAU04580 ON ...

Page 19: ...cator light This indicator light comes on when the low beam of the headlight is switched on 1 Low beam indicator light 2 Left turn signal indicator 3 Right turn signal indicator 4 High beam indicator light km h km h O 1O 1O 2O 2O 4O 4O 6O 6O 10O 10O 12O 12O 14O 14O 16O 16O 8O 8O km h km h O 1O 1O 2O 2O 4O 4O 6O 6O 10O 10O 12O 12O 14O 14O 16O 16O 8O 8O O 2O 2O 4O 4O 6O 6O 10O 10O 8O 8O mph mph 1 1 ...

Page 20: ...99 Battery voltage coolant temperature gauge When the key is turned to this gauge indicates the battery voltage level before the engine was stopped NOTE If the needle drops to the 9V mark have a Yamaha dealer check the battery When the key is turned to this gauge indicates the coolant temperature If the needle reaches the red zone stop the scooter and allow the engine to cool See page 6 17 for det...

Page 21: ...e speed traveled during this time a fuel reserve tripmeter which shows the distance traveled since the fuel level warning light came on a clock an ambient temperature display an oil change indicator which comes on when the engine oil should be changed NOTE For the UK the distance traveled is displayed in miles and the temperature reading is displayed in F For other countries the distance traveled ...

Page 22: ... the fuel level warning light comes on See page 3 3 the display will automatically change to the fuel reserve tripmeter mode Trip fuel and start counting the distance traveled from that point In that case pushing the MODE button switches the display between the various tripmeter and odometer modes in the following order Trip Fuel Trip 1 Trip 2 Total Trip fuel To reset a tripmeter select it by push...

Page 23: ...ts start flashing push the SET button to set the hours 3 Push the MODE button and the minute digits will start flashing 4 Push the SET button to set the minutes 5 Push the MODE button and then release it to start the clock The display will return to the Total mode Ambient temperature display This display shows the ambient temperature from 30 C 86 F to 50 C 122 F The frost warning indicator automat...

Page 24: ...set the indicator as follows 1 While holding the MODE and SET buttons pushed turn the key to 2 Continue holding 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 indicato...

Page 25: ...osition To cancel the turn si gnal lights push the switch in after it has returned to the center position EAU00129 Horn switch Press this switch to sound the horn 1 2 3 ZAUM0408 1 Engine stop switch 2 Hazard switch 3 Start switch EAU03890 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergency such as when the scooter overturns...

Page 26: ...gth of time otherwise the battery may discharge EAUM0111 Hazard switch With the key in the position 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 regardless of th...

Page 27: ...l position and then remove it NOTE Do not forget to remove the key before closing the seat 3 Close the seat NOTE The fuel tank cap cannot be installed unless the key is in the lock In addi tion the key cannot be removed if the cap is not properly installed and locked EW000023 Make sure that the fuel tank cap is properly closed and locked before riding WARNING 1 2 ZAUM0020 1 Filler tube 2 Fuel leve...

Page 28: ...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 CAUTION EAU03098 Catalytic converter This scooter is equipped with a catalytic converter in the muffler EW000128 The exhaust system is hot after operation Make sure that the exhaust system has cooled down before doing ...

Page 29: ... the scooter will be left unattended NOTE Make sure that the seat is properly secured before riding O P E N OPEN UNLOCK LOCK OPEN OPEN UNLOCK LOCK O P E N OPEN UNLOCK LOCK 1 2 ZAUM0411 1 Lock 2 Front storage compartment A EAUM0096 Storage compartments Front storage compartment A To unlock the storage compartment Insert the key in the lock and turn it 1 4 turn clockwise To open the storage compartm...

Page 30: ...ore heavy items in this compartment WARNING 1 ZAUM0413 1 Front storage compartment B EAUM0061 Rear storage compartment There is a storage compartment under the seat See page 3 12 for seat opening and closing procedures EWA00005 Do not exceed the load limit of 5 kg for the storage compartment Do not exceed the maximum load of 202 kg for the vehicle WARNING 3 13 EAUM0101 Front storage compartment B ...

Page 31: ...d in the storage compartment because of their size or shape Do not leave your scooter unattended with the seat open CAUTION 1 2 3 4 1 a b 2 ZAUM0414 1 Spring preload adjusting ring 2 Position indicator EAU00300 Adjusting the shock absor ber assemblies Each shock absorber assembly is equipped with a spring preload adjusting ring EC000015 Never attempt to turn an adjusting mechanism beyond the maxim...

Page 32: ...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 NOTE Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber WARNING Setting Minimum soft 1 Standard 2 Maximum hard 4 1 ZAUM0415 1 Luggage hook EAUT0020 Luggage hook EWT00002 Do not exceed the loa...

Page 33: ...it cut off system has been designed to assist the operator in fulfilling the responsibility of raising the sidestand before starting off Therefore check this system regularly as described below and have a Yamaha dealer repair it if it does not function properly 1 Sidestand switch WARNING EAU00337 Ignition circuit cut off system The ignition circuit cut off system comprising the sidestand switch an...

Page 34: ...rt The brake 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...

Page 35: ...es connected to the auxiliary DC jack should not be used with the engine turned off and their combined load must never exceed 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 receptacle 3 Insert the accessory plug into the receptacle 4 Turn the key to and then start the engine See page 5 1 for details 5 When the accesso...

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Page 37: ...EAU01114 PRE OPERATION CHECKS Pre operation check list 4 1 4 ...

Page 38: ...leakage Check oil level in engine Engine oil If necessary add recommended oil to specified level 6 13 6 15 Check vehicle for oil leakage Final transmission oil Check vehicle for oil leakage 6 16 Check coolant level in reservoir Coolant If necessary add recommended coolant to specified level 6 17 Check cooling system for leakage Check operation If soft or spongy have Yamaha dealer bleed hydraulic s...

Page 39: ...ry Brake levers Make sure that operation is smooth 3 9 6 23 6 26 Lubricate lever pivoting points if necessary Centerstand sidestand Make sure that operation is smooth 6 27 Lubricate pivots if necessary Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights Check operation 3 1 3 8 6 32 6 35 signals and switches Correct if necessary ...

Page 40: ... 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 EWA00033 If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the scooter WARNING 4 3 ...

Page 41: ...U00372 OPERATION AND IMPORTANT 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 ...

Page 42: ...e centerstand down WARNING EAU03843 Starting the engine See page 5 4 for engine break in ins tructions prior to operating the vehicle for the first time In order for the ignition circuit cut off system to enable starting the sidestand must be up EW000054 Before starting the engine check the function of the igni tion circuit cut off system according to the procedure described on page 3 16 Never rid...

Page 43: ...CA00045 For maximum engine life never accelerate hard when the engine is cold CAUTION 1 ZAUM0419 1 Grab bar EAU00433 Starting off 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 centerstand 2 Sit astride the seat and then adjust the rear view mirrors 3 Switch the tur...

Page 44: ...h front and rear brakes simultaneously while gradually increasing the pressure EW000057 Avoid braking hard or suddenly especially when leaning over to one side otherwise the scooter may skid or overturn Railroad crossings streetcar rails iron plates on road cons truction sites and manhole covers become extremely slippery when wet Therefore slow down when approaching such areas and cross them with ...

Page 45: ...ould read the following 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 themselves to the correct operating clearances During this period prolonged full throttle operation or any condition that might result in engine overheating must be avoided EAU03845 0 1 000 km Avoid prolonged operation ab...

Page 46: ...00058 Since the engine and exhaust system can become very hot park in a place where pedestrians or children are not likely to touch them Do not park on a slope or on soft ground otherwise the scooter may overturn EC000062 Never park in an area where there are fire hazards such as grass or other flammable materials WARNING CAUTION 5 5 ...

Page 47: ...y 6 23 Checking the front and rear brake pads 6 24 Checking the brake fluid level 6 24 Changing the brake fluid 6 25 Checking and lubricating the cables 6 26 Checking and lubricating the throttle grip and cables 6 26 Lubricating the front and rear brake levers 6 26 Checking and lubricating the centerstand and sidestand 6 27 Checking the front fork 6 27 Checking the steering 6 28 Checking the wheel...

Page 48: ...ter is operated in abnormally dusty muddy or wet conditions the air filter element should be cleaned or replaced more frequently otherwise rapid engine wear may result Consult a Yamaha dealer for proper maintenance intervals WARNING EAUT0027 Owner s tool kit The owner s tool kit is located inside the front storage compartment A See page 3 12 for front storage compartment opening procedures The ser...

Page 49: ... Yamaha dealer as they require special tools data and technical skills 1 Fuel line Check fuel hoses and vacuum hose for cracks or damage Check condition 2 Spark plug Clean and regap Replace 3 Valves Check valve clearance Adjust 4 Air filter element Clean Replace 5 V belt case air filter element Clean Check operation fluid level and vehicle for fluid leakage 6 Front brake See NOTE on page 6 4 Repla...

Page 50: ...el bearings Check bearing for looseness or damage 12 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20 000 km 13 Chassis fasteners 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 S...

Page 51: ...Check operation switches 25 Moving parts and cables Lubricate Throttle grip housing Check operation and free play 26 and cable Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 27 Lights signals Check operation and switches Adjust headlight beam ODOMETER READING x 1 000 km NO ITEM CHECK OR MAINTENANCE JOB 1 ANNUAL CHECK 10 20 30 40 EAU03884 NOTE The air...

Page 52: ...s The cowlings and panels 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 panel needs to be removed and installed 1 ZAUM0421 1 ZAUM0422 1 Cowling A 1 Cowling B 6 5 1 2 ZAUM0420 1 Windshield 2 Panel A ...

Page 53: ...PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 ZAUM0425 1 ZAUM0424 1 Panel B 1 Panel C 6 6 1 ZAUM0426 1 Panel D ...

Page 54: ...e scooter 2 Remove panel A See page 6 9 for removal and installation procedures 3 Remove the cowling screws 4 Disconnect the headlight coupler and the turn signal lead coupler 5 Pull the cowling off To install the cowling 1 Connect the headlight coupler and the turn signal lead coupler 2 Place the cowling in the original position and then install the screws 3 Install panel A 4 Place the floorboard...

Page 55: ...30 1 ZAUM0435 EAUM0106 Cowling B To remove the cowling 1 Pull up the floorboard mat on each side of the scooter 2 Remove the screws on each side of scooter and then take the cowling off To install the cowling 1 Place the cowling in the original position and then install the screws 2 Place the floorboard mats in their original position ...

Page 56: ...ws and then pull the panel out as shown To install the panel 1 Place the panel in the original po sition and then install the screws 2 Place the windshield in the origi nal position and then install the screws EAU01535 Panel B To remove the panel Remove the screw and then pull the panel off as shown To install the panel Place the panel in the original position and then install the screw 1 Screw x1...

Page 57: ...el 1 Pull up the right floorboard mat 2 Remove the panel as shown To install the panel 1 Place the panel in the original position 2 Place the floorboard mat in the original position EAU00494 Panel D To remove the panel Pull the panel off as shown To install the panel Place the panel in the original position 1 Panel D 1 ZAUM0437 ...

Page 58: ...in tenance and lubrication chart In addi tion the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove cowling B See page 6 8 for cowling removal and instal lation procedures 2 Remove the spark plug cap 1 Spark plug 6 11 1 ZAUM0438 1 2 ZAUM0585 EAU01535 Panel E To remove the panel Remove the screw and then pull the panel off as shown To install the p...

Page 59: ...ems yourself Instead have a Yamaha dealer check the scooter 2 Check the spark plug for electrode erosion and excessive carbon or other deposits and replace it if necessary Specified spark plug DR8EA NGK To install the spark plug 1 Measure the spark plug gap with a wire thickness gauge and if necessary adjust the gap to specification Spark plug gap 0 6 0 7 mm 2 Clean the surface of the spark plug g...

Page 60: ...ap 5 Install the cowling 6 13 EAUM0103 Engine oil The engine oil level should be checked before each ride In addition the oil must be changed at the intervals specified in the periodic maintenance and lubrication chart and when the oil change indicator comes on To check the engine oil level 1 Place the scooter on the centerstand NOTE Make sure that the scooter is positioned straight up when checki...

Page 61: ... NOTE The engine oil should be between the minimum and maximum level marks 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level 5 Insert the dipstick into the oil filler hole and then tighten the oil filler cap To change the engine oil 1 Start the engine warm it up for several minutes and then turn it off 2 Place an oil pa...

Page 62: ...nded engine oil and then install and tighten the oil filler cap Recommended engine oil See page 8 1 Oil quantity Periodic oil change 1 2 L Total amount dry engine 1 4 L 7 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 8 Reset the oil change indicator See page 3 7 for details ECA00...

Page 63: ...used oil 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 Tightening torque Final transmission oil drain bolt 22 Nm 2 2 m kgf 6 Add the specified amount of the recommended final transmission oil and then install and tighten the oil filler cap 1 Final transmission ...

Page 64: ...ature Make sure that the scooter is positioned straight up when checking the coolant level Aslight tilt to the side can result in a false reading 2 Check the coolant level in the coolant reservoir NOTE The coolant should be between the minimum and maximum level marks 1 Maximum level mark 2 Minimum level mark 3 If the coolant is at or below the minimum level mark remove the reservoir cap add coolan...

Page 65: ... coolant temperature in the radiator If the engine overheats see page 6 37 for further instructions CAUTION EAU03627 Air filter and V belt case air filter elements The air filter and V belt case air filter elements should be cleaned at the intervals specified in the periodic main tenance and lubrication chart Clean both filter elements more frequently if you are riding in unusually wet or dusty ar...

Page 66: ...f the recommended type to the entire surface of the sponge material and then squeeze the excess oil out NOTE The sponge material should be wet but not dripping Recommended oil Engine oil 7 Insert the sponge material into the air filter case 8 Install the air filter case cover by installing the screws Cleaning the V belt case air filter element 1 Remove the V belt case air filter cover by removing ...

Page 67: ...ent EAU00631 Adjusting the carburetor The carburetor is an important part of the engine and requires very sophisticated adjustment Therefore all carburetor adjustments should be left to a Yamaha dealer who has the necessary professional knowledge and experience EAU00635 Adjusting the throttle cable free play The throttle cable free play should measure 1 5 3 mm at the throttle grip Periodically che...

Page 68: ...ecked and if necessary adjusted before each ride EW000082 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 adjusted in accordance with the riding speed and with the total weight of rider passenger cargo and accessories approved for this model WARNING Maximum load 202 kg Total weight o...

Page 69: ...items close to the center of the scooter and distribute the weight evenly on both sides Adjustthesuspensionandtireair pressure with regard to the load Check the tire condition and air pressure before each ride WARNING 1 Tire tread depth 2 Sidewall Tire information This scooter is equipped with tubeless tires Front Manufacturer Size Type MICHELIN 120 80 14 58P PILOT CITY TL Rear Manufacturer Size T...

Page 70: ...an result in poor performance adverse handling characteristics and a shortened 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 characteristics EAUM0056 Adjusting the front and rear brake lever free play The front and rear brake lever free play should measure 2 5 mm as shown Periodically check the front and rear b...

Page 71: ...a dealer replace the brake pads as a set a Wear limit a Wear limit 1 Minimum level mark EAU04856 Checking the brake fluid level 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 above the minimum level mark and replenish if necessary Alow brake fluid level may indicate worn brake pads and or brake ...

Page 72: ...es not enter 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 painted surfaces or plastic parts Always clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to gradually go down However if the brake fluid level goes down suddenly have a Yamaha d...

Page 73: ... will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe con ditions WARNING EAU04034 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 EAU03118 Lubricating the front an...

Page 74: ...oothly have a Yamaha dealer check or repair it 1 Sidestand 1 Centerstand WARNING Recommended lubricant Lithium soap based grease all purpose grease EAU02939 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 EW000115 Securely support the scooter so that...

Page 75: ...ir it CAUTION EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground EW000115 Securely support the scooter so that there is no danger of it falling over WARNI...

Page 76: ...enance There is no need to check the electrolyte or to add distilled water 1 Battery 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 discharge more quickly if the scooter is equipped with optional electrical accessories EW000116 Electrolyte is poisonous and dangerous since it contains sulfuric a...

Page 77: ...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 EC000102 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant vol tage battery charger is required Using a conventional battery charger will...

Page 78: ...key to and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage Specified fuses Main fuse Box Main fuse 30 A Fuse block Backup fuse 3 A Headlight fuse 15 A Radiator fan fuse 15 A Signaling system fuse 15 A Ignition fuse 7 5 A Auxiliary DC jack fuse 3 A 3 Turn the key to and turn on the electrical circuit in question to check if t...

Page 79: ...val and installa tion procedures WARNING 1 Bulb cover 2 Headlight coupler 3 Remove the headlight bulb holder by pushing it inward and turning it counterclockwise and then remove the defective bulb EW000119 Headlight bulbs get very hot Therefore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 2 Disconnect the headlight coupler and then remov...

Page 80: ...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 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 a Do not touch the g...

Page 81: ...Remove the defective bulb by pushing it in and turning it counterclockwise 5 Insert a new bulb into the socket push it in and then turn it clockwise until it stops 6 Install the socket together with the bulb by turning it clockwise 7 Install the cowling 1 Turn signal socket x2 EAUT0021 Replacing the tail brake light bulb or a rear turn signal light bulb 1 Place the scooter on the centerstand 2 Rem...

Page 82: ...5 Install the socket together with the bulb by pushing it in 6 Install the license plate light cover by installing the screw EAU03087 Troubleshooting Although Yamaha scooters receive a thorough inspection before shipment from the factory trouble may occur during operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following tro...

Page 83: ...pression 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...

Page 84: ...cape When the hissing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap WARNING 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...

Page 85: ...EAU03434 SCOOTER CARE AND STORAGE Care 7 1 Storage 7 3 7 ...

Page 86: ...covers as well as all electrical couplers 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 Avoid using strong acidic wheel cleaners especially on ...

Page 87: ...not 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 bottlebrush 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...

Page 88: ...ke discs and brake linings with a regular brakedisccleaneroracetone and wash the tires with warm water and a mild detergent Before operating the scooter test its braking performance and cornering behavior Storage Short term Always store your scooter in a cool dry place and if necessary protect it against dust with a porous cover ECA00015 Storing the scooter in a poorly ventilated room or covering ...

Page 89: ... 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 EWA00003 To prevent damage or injury from sparking make sure to ground the spark plug electrodes while turning the engine over 5 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centers...

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Page 91: ...EAU01038 SPECIFICATIONS Specifications 8 1 Conversion table 8 4 8 ...

Page 92: ... ratio 10 1 Starting system type Electric starter Lubrication system Wet sump Specifications Engine oil Type 20 10 10 20 30 40 50 C 0 SAE 10W 30 SAE 10W 40 SAE 15W 40 SAE 20W 40 SAE 20W 50 Recommended engine oil API Service SE SF SG type Classification or higher CAUTION 8 1 Be sure to use motor oils that do not contain anti fric tion modifiers Passenger car motor oils often labeled Energy Conservi...

Page 93: ...ar Secondary reduction ratio 37 12 3 083 Transmission type V belt automatic Operation Centrifugal automatic type Chassis Frame type Steel tube underbone Caster angle degree 26 Trail 90 mm Tires Front Type Tubeless Size 120 80 14 58P Manufacturer Model MICHELIN PILOT CITY TL Rear Type Tubeless Size 150 70 14 66P Manufacturer Model MICHELIN PILOT CITY TL Maximum load 202 Kg Air pressure cold tire Up...

Page 94: ...el travel 108 mm Rear wheel travel 120 mm Electrical Ignition system type Transistorized coil ignition Charging system AC magneto Battery Model F9 12B Voltage capacity 12 V 9 Ah Headlight type Halogen bulb Bulbs voltage wattage x quantity Headlight 12V 35W 35Wx2 Auxiliary light 12V 5Wx2 Tail brake light 12V 5W 21Wx2 Turn signal light Front 12V 21Wx2 Rear 12V 10Wx2 High beam indicator light LED Tur...

Page 95: ...SPECIFICATIONS 8 EAU04513 Conversion table 8 4 ...

Page 96: ......

Page 97: ...9 EAU01039 CONSUMER INFORMATION Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 ...

Page 98: ...ation 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 EAU01044 Vehicle identification number The vehicle identification number is stamped into the frame behind the panel D See page 6 10 for panel removal and installation procedures NOTE The vehicle identification number is used to identify yo...

Page 99: ...l label is affixed to the bottom of the seat See page 3 12 for seat opening procedures Record the infor mation on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 9 2 1 ZAUM0469 1 Model label ...

Page 100: ...7 Conversion table 8 4 Coolant 6 17 Cowlings and panels removing and installing 6 5 E Engine break in 5 4 Engine oil 6 13 F Final transmission oil 6 16 Front and rear brake lever free play adjusting 6 23 Front fork checking 6 27 Fuel 3 10 Fuel consumption tips for reducing 5 4 Fuel gauge 3 3 Fuel tank cap 3 10 Fuses replacing 6 30 H Handlebar switches 3 8 Dimmer switch 3 8 Engine stop switch 3 8 H...

Page 101: ...rance adjusting 6 21 Vehicule identification number 9 1 W Wheel bearing checking 6 29 Wheels 6 23 Luggage hook 3 15 M Main switch steering lock 3 1 Model label 9 2 Multi function display 3 4 P Parking 5 5 Part locations 2 1 Periodic maintenance and lubrication chart 6 2 Pre operation check list 4 1 S Safe riding points 1 2 Seat 3 12 Shock absorber assemblies adjusting 3 14 Sidestand 3 16 Spark plu...

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Page 104: ...PRINTED IN FRANCE 2004 02 E YAMAHA MOTOR CO LTD ...

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