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Yamaha XP500 Owner'S Manual Download Page 71

6-26

PERIODIC MAINTENANCE AND MINOR REPAIR

6

EAU03938

Front brake pads

Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear
without having to disassemble the
brake. To check the brake pad wear,
check the wear indicator grooves. If a
brake pad has worn to the point that
the wear indicator grooves have
almost disappeared, have a Yamaha
dealer replace the brake pads as a
set.

1

1

1

1

1.

Brake pad wear indicator groove (

×

3)

EAU00721

Checking the front and rear
brake pads

Front and rear brake pads, checking

The front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart.

REAR

FRONT

5GJ-28199-E2  9/9/02 9:15 AM  Page 69

Summary of Contents for XP500

Page 1: ...OWNER S MANUAL 5GJ 28199 E2 XP500 ...

Page 2: ...5GJ 28199 E2 9 9 02 9 15 AM Page 6 ...

Page 3: ...ughly so as to enjoy all advantages of your XP500 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 informati...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 w PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS SCOOTER 5GJ 28199 E2 9 9 02 9 15 AM Page 3 ...

Page 6: ...aha Motor Co Ltd 1st edition August 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 5GJ 28199 E2 9 9 02 9 15 AM Page 4 ...

Page 7: ...TION 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 5GJ 28199 E2 9 9 02 9 15 AM Page 5 ...

Page 8: ...5GJ 28199 E2 9 9 02 9 15 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 5GJ 28199 E2 9 9 02 9 15 AM Page 7 ...

Page 10: ...f 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 shoul...

Page 11: ...r 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 ...

Page 12: ...5GJ 28199 E2 9 9 02 9 15 AM Page 10 ...

Page 13: ...DESCRIPTION Left view 2 1 Right view 2 2 Controls and instruments 2 3 2 5GJ 28199 E2 9 9 02 9 15 AM Page 11 ...

Page 14: ...4 Grab bar page 5 2 5 Chain drive oil filler cap page 6 15 6 Engine oil filler cap page 6 13 7 V belt air filter element left 8 Engine oil drain bolt page 6 13 9 Engine oil level check window page 6 12 10 Oil filter cartridge page 6 13 1 2 3 4 9 8 7 6 5 10 Part locations Left view 5GJ 28199 E2 9 9 02 9 15 AM Page 12 ...

Page 15: ...t storage compartment page 3 14 14 Windshield 15 Air filter element page 6 19 16 Radiator 17 Coolant level check window page 6 17 18 V belt air filter element right 19 Centerstand page 6 29 20 Passenger footrest 11 12 13 14 15 18 17 16 19 20 Right view 5GJ 28199 E2 9 9 02 9 15 AM Page 13 ...

Page 16: ... Speedometer unit page 3 4 5 Coolant temperature gauge page 3 5 6 Fuel gauge page 3 4 7 Right handlebar switches page 3 7 8 Front brake lever page 3 9 9 Throttle grip page 6 22 6 29 10 Main switch steering lock page 3 1 4 3 2 5 6 7 8 1 10 9 Controls and instruments 5GJ 28199 E2 9 9 02 9 15 AM Page 14 ...

Page 17: ...ck 3 5 Self diagnosis device 3 6 Anti theft alarm optional 3 6 Handlebar switches 3 6 Front brake lever 3 9 Rear brake lever 3 9 Fuel tank cap 3 9 Fuel 3 10 Seat 3 11 Adjusting the rider backrest 3 12 Shock absorber 3 13 Helmet holder 3 13 Storage compartments 3 14 Sidestand 3 14 Ignition circuit cut off system 3 15 3 5GJ 28199 E2 9 9 02 9 15 AM Page 15 ...

Page 18: ...until 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 ...

Page 19: ...indicated at the correct time See page 6 15 for the resetting procedure The electrical circuit of the indicator light can be checked according to the following procedure 1 Set the engine stop switch to and turn the key to ON 2 Check that the indicator comes on for a few seconds and then goes off 3 If the indicator light does not come on have a Yamaha dealer check the electrical circuit EAU00056 In...

Page 20: ...n the key to ON and make sure that the engine stop switch is set to 2 If the indicator light does not come on have a Yamaha dealer check the electrical circuit 12 3 4 1 Oil change indicator light 7 2 V belt replacement indicator light V BELT 3 High beam indicator light 4 Turn signal indicator lights 4 and 6 EAU00063 High beam indicator light High beam indicator light This indicator light comes on ...

Page 21: ... fuel tank The needle moves towards E Empty as the fuel level decreases When the nee dle reaches the red line refuel as soon as possible NOTE Do not allow the fuel tank to empty itself completely 1 2 1 Fuel gauge 2 Red line Pushing the Trip button switches the display between the odometer mode ODO and the tripmeter mode TRIP To reset the tripmeter enter the TRIP mode and then hold down the Trip bu...

Page 22: ...t is overheated INSTRUMENT AND CONTROL FUNCTIONS 3 2 1 1 Coolant temperature gauge 2 Red mark EAU04402 Clock Clock The digital clock shows the time regardless of the main switch posi tion To set the clock 1 Push or hold the hour setting button h to change the hours 2 Push or hold the minute setting button m to change the min utes 1 2 3 1 Digital clock 2 Hour setting button h 3 Minute setting butto...

Page 23: ...engine is revved with the scooter on the centerstand but this does not indicate a malfunction EAU00118 Handlebar switches Handlebar switches EAU00120 Pass switch PASS Pass switch Press this switch to flash the head light EAU03888 Dimmer switch Dimmer switch Set this switch to for the high beam and to for the low beam 1 2 3 4 1 Pass switch PASS 2 Dimmer switch 3 Turn signal switch 4 6 4 Horn switch...

Page 24: ...ase of an emer gency such as when the scooter overturns or when the throttle cable is stuck 1 2 3 1 Engine stop switch 2 Hazard switch 0 3 Start switch EAU03826 Hazard switch 0 Hazard switch With the key in the ON or posi tion use this switch to turn on the hazard light simultaneous flashing of all turn signal lights The hazard light is used in case of an emergency or to warn other drivers when yo...

Page 25: ...adlight variations 1 2 Left Right Aux Bulb to be used Destination 2 1 1 3 1 3 2 1 Halogen bulb Halogen bulb Germany Belgium Switzerland Spain France Greece Italy Netherlands Norway Portugal Sweden England 3 High beam light on 2 Low beam light on Auxiliary light on 1 Light off 12V 55W 12V 60 55W 12V 60 55W 12V 55W 5GJ 28199 E2 9 9 02 9 15 AM Page 23 ...

Page 26: ...Rear brake lever Brake lever 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 EAU03881 Fuel tank cap Fuel tank cap To remove the fuel tank cap 1 Open the lid by pulling the lever up 2 Insert the key into the lock and turn it clockwise The lock will be released and the fuel tank cap can be removed...

Page 27: ...n place before riding the scooter 1 1 Match marks EAU00185 cC Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted sur faces or plastic parts EAU03753 Fuel Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown EW000130 w 8 8 Do not overfill the fuel tank otherwise it may overflow when the fu...

Page 28: ... 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 mainte nance costs EAU03802 Seat 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 counter clockwise NOTE Do not push inward when turning the key 3 Fold the seat up IGNITI O N P LOC...

Page 29: ... seat See page 3 11 for seat opening and closing pro cedures 2 Remove the backrest bolts 3 Slide the backrest forward or backward to the desired position 4 Install and securely tighten the backrest bolts 5 Close the seat 1 2 1 Rider backrest 2 Bolt 2 EAU03880 Adjusting the rider backrest Rider backrest adjusting The rider backrest can be adjusted to the three different positions shown Adjust the b...

Page 30: ...aler service the shock absorber INSTRUMENT AND CONTROL FUNCTIONS 3 EAU03879 Helmet holder Helmet holder The helmet holder is located under the seat A helmet holding cable is provided beside the owner s tool kit to secure a helmet to the helmet holder To secure a helmet to the helmet holder 1 Open the seat See page 3 11 for opening procedures 2 Pass the helmet holding cable through the buckle on th...

Page 31: ...with your foot while holding the scooter upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situ ations See further down for an explanation of the ignition circuit cut off system Rear storage compartment A helmet can be stored in the com partment under the seat See page 3 11 for seat opening and closing procedures ECA00079 c...

Page 32: ... does not function properly INSTRUMENT AND CONTROL FUNCTIONS 3 EAU00337 Ignition circuit cut off system Ignition circuit cut off system The ignition circuit cut off system comprising the sidestand switch and brake light switches has the follow ing functions 8 It prevents starting when the sidestand is up but neither brake is applied 8 It prevents starting when either brake is applied but the side ...

Page 33: ... 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 34: ...5GJ 28199 E2 9 9 02 9 15 AM Page 32 ...

Page 35: ...PRE OPERATION CHECKS Pre operation check list 4 1 4 5GJ 28199 E2 9 9 02 9 15 AM Page 33 ...

Page 36: ... fuel line for leakage 3 4 3 9 3 11 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 12 6 15 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 17 6 18 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check f...

Page 37: ... housing 6 22 6 29 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 6 23 6 25 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 3 9 6 29 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 29 6 30 Chassis fasteners Make sure that all nuts bolts and screws ar...

Page 38: ...5GJ 28199 E2 9 9 02 9 15 AM Page 36 ...

Page 39: ...PORTANT RIDING POINTS Starting the engine 5 1 Starting off 5 2 Acceleration and deceleration 5 2 Braking 5 3 Tips for reducing fuel consumption 5 3 Engine break in 5 4 Parking 5 4 5 5GJ 28199 E2 9 9 02 9 15 AM Page 37 ...

Page 40: ... 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 procedure described on page 3 16 8 8 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engin...

Page 41: ...nd then adjust the rear view mirrors 3 Switch the turn signal on 4 Check for oncoming traffic and then slowly turn the throttle grip on the right in order to take off 5 Switch the turn signal off EAU00434 Acceleration and deceleration Acceleration and deceleration The speed can be adjusted by open ing and closing the throttle To increase the speed turn the throttle grip in direction a To reduce th...

Page 42: ...w down when approaching such areas and cross them with caution 8 8 Keep in mind that braking on a wet road is much more diffi cult 8 8 Ride slowly down a hill as braking downhill can be very difficult EAU04755 Tips for reducing fuel consumption Fuel consumption tips for reducing Fuel consumption depends largely on your riding style Consider the follow ing tips to reduce fuel consumption 8 Avoid hi...

Page 43: ...0 1 000 km Avoid prolonged operation above 1 3 throttle 1 000 1 600 km Avoid prolonged operation above 1 2 throttle ECA00080 cC After 1 000 km of operation the engine oil must be changed and the oil filter cartridge replaced 1 600 km and beyond The vehicle can now be operated normally EC000049 cC If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer ...

Page 44: ...5GJ 28199 E2 9 9 02 9 15 AM Page 42 ...

Page 45: ...sting the valve clearance 6 22 Tires 6 23 Cast wheels 6 25 Front and rear brake levers 6 25 Checking the front and rear brake pads 6 26 Checking the brake fluid level 6 27 Changing the brake fluid 6 28 Checking and lubricating the throttle grip and cable 6 29 Lubricating the front and rear brake levers 6 29 Checking and lubricating the centerstand and sidestand 6 29 Checking the front fork 6 30 Ch...

Page 46: ... is located under the seat See page 3 11 for seat opening and closing procedures The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of pre ventive maintenance and minor repairs However additional tools such as a torque wrench may be nec essary to perform certain mainte nance work correctly 2 1 1 Helmet holdin...

Page 47: ...eri 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 Yamaha dealer before attempting any changes 5GJ 28199 E2 9 9 02 9 15 AM Page 45 ...

Page 48: ...as they require special tools data and technical 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 Fuel filter Check condition 3 Spark plugs Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust Every 40 000 km 5 Air filter element Clean Replace 6 V belt case air f...

Page 49: ...ring for looseness or damage 13 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20 000 km 14 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 15 Sidestand centerstand Check operation Lubricate 16 Sidestand switch Check operation 17 Front fork Check operation and for oil leakage 18 Shock absorber assembl...

Page 50: ...e indicator light 4 000 km after initial 1 000 km When the oil change indicator light comes on every 5 000 km Check oil level and vehicle for oil leakage Every 5 000 km 21 Engine oil filter cartridge Replace 22 Cooling system Check coolant level and vehicle for coolant leakage Change Every 3 years 23 Chain drive oil Check vehicle for oil leakage Change 24 V belt Replace When the V belt replacement...

Page 51: ...escribed in this chapter Refer to this section each time a cowling or panel needs to be removed and installed 4 3 1 2 1 Panel A 2 Panel B 3 Panel C 4 Cowling A EAU03878 Panels A and D To remove one of the panels 1 Remove panel C right side or panel E left side 2 Remove the panel screws 3 Pull outward on the front of the panel 1 1 Screw 3 1 2 3 4 5 1 Panel D 2 Cowling B 3 Panel E 4 Cowling C 5 Pane...

Page 52: ...off and then remove the panel screws To install the panel Place the panel in the original posi tion install the screws and then place the floorboard mat back 1 1 Screw 4 Panel B To remove the panel Remove the panel screws and then pull outward on the areas shown To install the panel Place the panel in the original posi tion and then install the screws 1 1 1 Screw 3 5GJ 28199 E2 9 9 02 9 15 AM Page...

Page 53: ...y installing the nuts 2 1 2 1 Screw 2 2 Nut 4 Cowling B To remove the cowling 1 Remove panels C and E 2 Remove the cowling screws and bolts 3 Unhook the cowling from the holder at the bottom 4 Unhook the front of the cowling by pushing it up and then pull the cowling out 1 2 1 Bolt 2 2 Screw 2 Panel F To remove the panel Remove the panel screws To install the panel 1 Place the panel in the origina...

Page 54: ... to slowly erode the spark plugs should be removed and checked in accordance with the periodic maintenance and lubrication chart In addition the condition of the spark plugs can reveal the condition of the engine Cowling C To remove the cowling 1 Remove the cowling bolts 2 Remove the battery cover by removing the screws 3 Pull the cowling off To install the cowling 1 Install the battery cover by i...

Page 55: ... removal and installation procedures 2 Remove the spark plug cover by pulling it out as shown 1 1 Spark plug cover 4 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit 1 1 Spark plug wrench 3 Remove the spark plug cap 1 1 Spark plug cap 5GJ 28199 E2 9 9 02 9 15 AM Page 53 ...

Page 56: ...ace it if necessary NOTE If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 4 Install the spark plug cap To install a spark plug 1 Measure the spark plug gap with a wire thickness gauge and if necessary adjust the gap to specif...

Page 57: ...el mark 3 Minimum level mark EAU04621 Engine oil and oil filter cartridge Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter cartridge replaced at the inter vals specified in the periodic mainte nance and lubrication chart To check the engine oil level 1 Place the scooter on the center stand ECA00081 cC...

Page 58: ...at of engine oil to the O ring of the new oil filter cartridge NOTE Make sure that the O ring is properly seated 2 1 1 Oil filter wrench 2 Oil filter cartridge To change the engine oil with or without oil filter cartridge replace ment 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...

Page 59: ...sure that no foreign material enters the crankcase 9 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 10 Turn the engine off and then check the oil level and correct it if necessary 8 Add the specified amount of the recommended engine oil and then install and tighten the oil filler ...

Page 60: ...in drive case to collect the used oil 3 Remove the oil filler cap and drain bolt to drain the oil from the chain drive case 1 2 1 Chain drive oil filler cap 2 Chain drive oil drain bolt NOTE If the engine oil is changed before the oil change indicator light comes on i e before the periodic oil change interval has been reached the indi cator light must be reset after the oil change for the next per...

Page 61: ...o foreign material enters the chain drive case NOTE The engine oil should be between the minimum and maximum level marks 7 If the engine oil is below the min imum level mark add sufficient oil of the recommended type to raise it to the correct level 8 Insert the dipstick into the oil filler hole and then tighten the oil filler cap 1 2 1 Maximum level mark 2 Minimum level mark Tightening torque Cha...

Page 62: ... tem perature 8 Make sure that the scooter is positioned straight up when checking the coolant level A slight tilt to the side can result in a false reading 3 Check the coolant level in the coolant reservoir NOTE The coolant should be between the minimum and maximum level marks 1 2 1 Maximum level mark 2 Minimum level mark 2 Remove the coolant reservoir cover by removing the screw 1 2 1 Coolant re...

Page 63: ...page 6 38 for further instructions EC000080 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...

Page 64: ... tion chart Clean the air filter element more frequently if you are riding in unusually wet or dusty areas 1 Remove cowling A See page 6 8 for cowling removal and installation procedures 3 Remove the air filter case cover by removing the screws and then pull the air filter element out 1 2 2 1 Air filter case cover 2 Screw 4 2 Remove the windshield by removing the screws 1 1 1 Screw 5 5GJ 28199 E2 ...

Page 65: ...otherwise the pistons and or cylinders may become excessively worn 6 Install the air filter case cover by installing the screws 7 Install the windshield and the cowling 4 Lightly tap the air filter element to remove most of the dust and dirt and then blow the remaining dirt out with compressed air as shown If the air filter element is damaged replace it 5 Insert the air filter element into the air...

Page 66: ...k the engine idling speed and if necessary adjust it to specification by turning the throt tle stop screw To increase the engine idling speed turn the screw in direction a To decrease the engine idling speed turn the screw in direction b 1 a b 1 Throttle stop screw EAU04758 Adjusting the engine idling speed Engine idling speed The engine idling speed must be checked and if necessary adjusted as fo...

Page 67: ...l 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 Throttle cable free play adjusting The throttle cable free play should measure 3 5 mm at the throttle grip Periodically check the throttle cable free play a...

Page 68: ...hift 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 8 8 Adjust the tire air pressure with regard to the load 8 8 Check the tire condition and air pressure before each ride EWA00040 w Because loading has an enormous impact on the handling braking performance and safety character istics of your scooter you should k...

Page 69: ...ead to loss of control 8 8 The replacement of all wheel and brake related parts including the tires should be left to a Yamaha dealer who has the necessary profession al knowledge and experience Tire information This scooter is equipped with cast wheels and tubeless tires EW000078 w 8 8 The front and rear tires should be of the same make and design otherwise the handling characteristics of the sco...

Page 70: ...heel A deformed or cracked wheel 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 EAU03851 Front and rear brake levers There should be no free play at the brake lever ends If there is free play have a Yamaha dealer inspect the b...

Page 71: ...cator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disappeared have a Yamaha dealer replace the brake pads as a set 1 1 1 1 1 Brake pad wear indicator groove 3 EAU00721 Checking the front and rear brake pads Front and rear brake pads checking The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and...

Page 72: ...que a 1 1 Bolt 2 a Brake pad wear limit EAU04856 Checking the brake fluid level Brake fluid level 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 above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If th...

Page 73: ...replaced at the intervals listed below or whenever they are damaged or leaking 8 Oil seals Replace every two years 8 Brake hoses Replace every four years 8 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking perfor mance 8 Be careful that water does not enter the brake fluid reservoir when refilling Water will signifi cantly low...

Page 74: ...king and lubricating 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 Brake levers lubricating The pivoting poi...

Page 75: ...ot operate smoothly have a Yamaha dealer check or repair it EAU02939 Checking the front fork Front fork 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 s...

Page 76: ...rely support the scooter so that there is no danger of it falling over EAU01144 Checking the wheel bearings Wheel bearings 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 ...

Page 77: ... 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 access the battery 1 Open the seat See page 3 11 for seat opening and closing pro cedures 2 Remove the battery cover by removing the screws 1 2 1 Screw 3 2 Ba...

Page 78: ...ent ventilation when charging it in an enclosed space 8 8 KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN 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 cha...

Page 79: ...in ques tion 2 Remove the blown fuse and then install a new fuse of the specified amperage 7 1 2 3 4 5 6 1 Signaling system fuse 2 Headlight fuse 3 Ignition fuse 4 Radiator fan fuse 5 Hazard fuse 6 Clock fuse backup fuse 7 Spare fuse 2 3 Disconnect the negative battery lead and then lift the battery as shown The fuse box which contains the fuses for the individual circuits is located under the bat...

Page 80: ...the headlight bulb holder as shown and then remove the defective bulb a 1 1 Headlight bulb holder a Unhook EAU03874 Replacing a headlight bulb Headlight bulb replacing This scooter is equipped with quartz bulb headlights If a headlight bulb burns out replace it as follows 1 Disconnect the headlight cou pler and then remove the head light bulb cover 1 2 1 Headlight coupler 2 Headlight bulb cover Sp...

Page 81: ...r 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 scooter properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bi...

Page 82: ...on There is no compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs 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 st...

Page 83: ... When the hissing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap 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 Check the cooling system for leakage Have a Yamaha dealer check and repair the cooling system Add coolant See NOTE Start the engine If the engine ov...

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Page 85: ...SCOOTER CARE AND STORAGE Care 7 1 Storage 7 4 7 5GJ 28199 E2 9 9 02 9 15 AM Page 83 ...

Page 86: ...s 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 ...

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 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 minute...

Page 88: ...Wax 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 behavi...

Page 89: ... 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 cylinders piston rings etc from corrosion a Remove the spark plug caps and the spark plugs b Pour a teaspoonful of engine oil into the spark plug bores c Install the spark plug caps onto the ...

Page 90: ...little 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 batt...

Page 91: ...SPECIFICATIONS Specifications 8 1 Conversion table 8 5 8 5GJ 28199 E2 9 9 02 9 15 AM Page 89 ...

Page 92: ...em Electric starter Lubrication system Dry sump Engine oil Type SAE 10W 30 or 10W 40 Recommended engine oil classification API Service SE SF SG type or higher cC In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils...

Page 93: ...ry reduction ratio 41 25 40 29 2 262 Transmission type V belt automatic Operation Centrifugal automatic type Chassis Frame type Diamond Caster angle 28 Trail 95 mm Tires Front Type Tubeless Size 120 70 14M C 55S Manufacturer DUNLOP D305FA model BRIDGESTONE HOOP B03 Rear Type Tubeless Size 150 70 14M C 66S Manufacturer DUNLOP D305 model BRIDGESTONE HOOP B02 Maximum load 183 kg Air pressure cold tir...

Page 94: ...scopic fork Rear Swingarm Spring shock absorbers Front Coil spring oil damper Rear Coil spring gas oil damper Wheel travel Front 120 mm Rear 120 mm Electrical Ignition system Transistorized coil ignition digital Charging system Type A C magneto Standard output 14 V 310W 5 000 r min Battery Type GT9B 4 Voltage capacity 12 V 8 Ah Headlight bulb type Halogen Bulb voltage wattage quantity Headlight 12...

Page 95: ... 1 Meter lighting 12 V 1 7 W 3 High beam indicator light 12 V 1 7 W 1 Oil change indicator light 12 V 1 7 W 1 Turn indicator light 12 V 3 4 W 2 V belt replacement indicator light 12 V 1 7 W 1 Fuses Main fuse 30 A Signaling system fuse 15 A Headlight fuse 15 A Ignition fuse 10 A Radiator fan fuse 15 A Hazard fuse 10 A Clock fuse backup fuse 10 A 5GJ 28199 E2 9 9 02 9 15 AM Page 93 ...

Page 96: ...YSTEM 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 M...

Page 97: ...CONSUMER INFORMATION Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 9 5GJ 28199 E2 9 9 02 9 15 AM Page 95 ...

Page 98: ...MATION EAU01041 Key identification number Key identification number 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 Vehicle identification number The vehicle identification number is stamped into the frame NOTE The vehicle identification number is used to iden...

Page 99: ...odel label The model label is affixed to the loca tion shown 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 5GJ 28199 E2 9 9 02 9 15 AM Page 97 ...

Page 100: ... 1 Periodic maintenance and lubrication chart 6 3 Pre operation check list 4 1 R Rider backrest adjusting 3 12 S Safe riding points 1 2 Seat 3 11 Self diagnosis device 3 6 Sidestand 3 14 Spark plugs checking 6 9 Specifications 8 1 Speedometer unit 3 4 Starting off 5 2 Starting the engine 5 1 Steering checking 6 31 Storage 7 4 Storage compartments 3 14 A Acceleration and deceleration 5 2 Air filter...

Page 101: ... cable checking and lubricating 6 29 Tires 6 23 Tool kit 6 1 Troubleshooting 6 36 Troubleshooting charts 6 37 V Valve clearance adjusting 6 22 Vehicle identification number 9 1 W Wheel bearings checking 6 31 Wheels 6 25 INDEX 5GJ 28199 E2 9 9 02 9 15 AM Page 99 ...

Page 102: ...5GJ 28199 E2 9 9 02 9 15 AM Page 100 ...

Page 103: ...5GJ 28199 E2 9 9 02 9 15 AM Page 6 ...

Page 104: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2002 9 0 5x1 E 5GJ 28199 E2_hyoushi 9 3 02 8 41 AM Page 1 ...

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