Yamaha MAJESTY YP250 Owner`s manual

5GM-9-E0(Hyoushi) 4/13/0 9:16 PM Page 1 (2,1)
(Magenta plate)
OWNER’S MANUAL
YP250
5GM-28199-E0
siro page 4/6/0 3:58 AM Page 1
5GM-9-E0 4/13/0 9:05 PM Page 1
EAU00001
INTRODUCTION
Welcome to the Yamaha world of motorcycling!
1
As the owner of a YP250, you are benefiting from Yamaha’s vast experience in and newest technology for the design and the manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
2
Please take the time to read this manual thoroughly, so as to enjoy all your YP250’s advantages. 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.
4
In addition, the many tips given in this manual will help to keep your scooter in the best possible condition. If you have any further questions, do not hesitate to contact your Yamaha dealer.
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The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!
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5GM-9-E0 4/13/0 9:05 PM Page 2
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
1
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
IS INVOLVED!
Q
2
3
4
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Failure to follow WARNING instructions could result in severe injury or death to
the scooter operator, a bystander or a person inspecting or repairing the scooter.
cC
A CAUTION indicates special precautions that must be taken to avoid damage to
the scooter.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
5
6
7
8
9
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 information available at the time of printing, there
may be minor discrepancies between your scooter and this manual. If there is any question
concerning this manual, please consult your Yamaha dealer.
EAU00005
5GM-9-E0 4/13/0 9:05 PM Page 3
IMPORTANT MANUAL INFORMATION
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EW000002
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING
THIS SCOOTER.
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EAU00008
YP250
OWNER’S MANUAL
©1999 by Yamaha Motor Co., Ltd.
1st Edition, October 1999
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
5GM-9-E0 4/13/0 9:05 PM Page 5
EAU00009
TABLE OF CONTENTS
1 GIVE SAFETY THE RIGHT OF WAY
1
2 DESCRIPTION
2
3 INSTRUMENT AND CONTROL FUNCTIONS
3
4 PRE-OPERATION CHECKS
4
5 OPERATION AND IMPORTANT RIDING POINTS
5
6 PERIODIC MAINTENANCE AND MINOR REPAIR
6
7 SCOOTER CARE AND STORAGE
7
8 SPECIFICATIONS
8
9 CONSUMER INFORMATION
9
INDEX
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GIVE SAFETY THE RIGHT OF WAY
GIVE SAFETY THE RIGHT OF WAY ................................................1-1
FURTHER SAFE RIDING POINTS FOR THIS MODEL ....................1-2
1
5GM-9-E0 4/13/0 9:05 PM Page 8
Q GIVE SAFETY THE RIGHT OF WAY
1
2
3
EAU00021
Scooters are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom.
However, they also impose certain limits, which you must accept; even the best scooter does not
ignore the laws of physics.
Regular care and maintenance are essential for preserving your scooter’s value and operating condition. Moreover, what is true for the scooter is also true for the rider: good performance depends on
being in good shape. Riding under the influence of medication, drugs and alcohol is, of course, out of
the question. Scooter riders more than car drivers must always be at their mental and physical best.
Under the influence of even small amounts of alcohol, there is a tendency to take dangerous risks.
4
5
6
7
Protective clothing is as essential for the scooter rider as seat belts are for car drivers and passengers. 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 protective wear, however, should not encourage carelessness. Though full-coverage helmets and suits,
in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable.
Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is
even more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensively
avoiding all dangers, including those caused by others.
8
Enjoy your ride!
9
1-1
5GM-9-E0 4/13/0 9:05 PM Page 9
Q GIVE SAFETY THE RIGHT OF WAY
EAU03099*
FURTHER SAFE RIDING POINTS FOR THIS MODEL
8 Be sure to signal clearly when making turns.
8 Braking can be extremely difficult on a wet road. Avoid hard braking, because the scooter could
slide. Apply the brakes slowly when stopping on a wet surface.
8 Slow down as you approach a corner or turn. Once you have completed a turn, accelerate slowly.
8 Be careful when passing parked cars. A driver might not see you and open a door in your path.
8 Street car rails, iron plates on road construction sites, and man-hole covers become extremely
slippery when wet. Slow down and cross them with caution. Keep the scooter upright. It could
slide out from under you.
8 The brake pads could get wet when you wash the scooter. After washing the scooter, check the
brakes before riding.
8 Always wear a helmet, gloves, trousers (tapered around the cuff and ankle so they do not flap),
and a bright colored jacket.
8 Do not carry too much luggage on the scooter. An overloaded scooter is unstable.
1
2
3
4
5
6
7
8
9
1-2
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1
2
3
4
5
6
7
8
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DESCRIPTION
Left view .............................................................................................2-1
Right view ...........................................................................................2-2
Controls/Instruments ..........................................................................2-3
2
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EAU00026
DESCRIPTION
Left view
1
2
1
2
3
4
5
6
7
8
8
7
6
5
4
3
9
1. Rear storage compartment
2. Grab bar
3. Rear shock absorber spring preload
adjusting ring
4. Air filter
(page 3-14)
(Page 5-2)
5.
6.
7.
8.
(page 3-15)
(page 6-16)
2-1
V-belt case air filter
Centerstand
Sidestand
Fuel tank cap
(page 6-17)
(page 6-24)
(page 3-16)
(page 3-10)
5GM-9-E0 4/13/0 9:05 PM Page 13
DESCRIPTION
Right view
9
1
2
10
3
11
4
5
6
7
8
17
9.
10.
11.
12.
13.
Rider seat
Air flow louver
Headlight
Radiator
Battery
16 15 13, 14
(page 3-12)
(page 6-18)
(page 6-28)
12
14.
15.
16.
17.
(page 6-26)
2-2
Fuse box
Coolant reservoir tank
Coolant level check window
Engine oil dipstick
9
(page 6-27)
(page 6-15)
(page 6-15)
(page 6-11)
5GM-9-E0 4/13/0 9:05 PM Page 14
EAU00026
DESCRIPTION
Controls/Instruments
18
19
20 21 22 23 24
25
26
1
2
3
4
5
6
7
29
8
9
18.
19.
20.
21.
22.
23.
Rear brake lever
Left handlebar switches
Front storage compartment A
Digital clock
Speedometer
Coolant temperature gauge
(page 3-10)
(page 3-6, 3-7)
(page 3-14)
(page 3-6)
(page 3-4)
(page 3-5)
24.
25.
26.
27.
28.
29.
2-3
28
27
Fuel gauge
Right handlebar switches
Front brake lever
Throttle grip
Front storage compartment B
Main switch/steering lock
(page 3-5)
(page 3-7, 3-9)
(page 3-9)
(page 3-14)
(page 3-1)
5GM-9-E0 4/13/0 9:05 PM Page 15
INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock....................................................................3-1
Indicator lights ....................................................................................3-2
Oil change indicator light circuit check ...............................................3-3
Speedometer .....................................................................................3-4
Diagnosis device ................................................................................3-4
Antitheft alarm (optional) ....................................................................3-5
Fuel gauge..........................................................................................3-5
Coolant temperature gauge................................................................3-5
Digital clock ........................................................................................3-6
Handlebar switches ............................................................................3-6
Headlight beam variation....................................................................3-8
Front brake lever ................................................................................3-9
Rear brake lever ...............................................................................3-10
Fuel tank cap ....................................................................................3-10
Fuel...................................................................................................3-11
Catalyzer ..........................................................................................3-12
Rider seat .........................................................................................3-12
Rider seat adjustment.......................................................................3-13
Storage compartments .....................................................................3-14
Rear shock absorber adjustment......................................................3-15
Carrier (optional)...............................................................................3-16
Sidestand..........................................................................................3-16
Sidestand switch operation check ....................................................3-17
3
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EAU00027
INSTRUMENT AND CONTROL FUNCTIONS
EAU00040
OFF
1
ON
OPEN
PUSH
N
PUSH
P
3
4
I G NI
O
2
LOCK
TI
EAU00029
Main switch/steering lock
5
6
The main switch controls the ignition
and lighting systems. Its operation is
described below.
EAU00036
7
8
9
ON
Electrical circuits are switched on.
The engine can be started. The key
cannot be removed in this position.
EAU00038
OFF
All electrical circuits are switched off.
The key can be removed in this position.
LOCK
The steering is locked in this position
and all electrical circuits are switched
off. The key can be removed in this
position.
To lock the steering, turn the handlebars all the way to the left. While
pushing the key into the main switch,
turn it from “OFF” to “LOCK” and
remove it.
To release the lock, turn the key to
“OFF” while pushing.
EW000016
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Never turn the key to “OFF” or
“LOCK” when the scooter is moving. The electrical circuits will be
switched off which may result in
loss of control or an accident. Be
sure the scooter is stopped before
turning the key to “OFF” or
“LOCK”.
3-1
EAU01433
.
(Parking)
The steering is locked in this position,
and the taillight, license light and auxiliary light come on, but all other circuits are off. The key can be
removed in this position.
To set the main switch to “ . ”:
1. Set the main switch to “LOCK”.
2. Slightly turn the key counterclockwise until it stops.
3. While still turning the key counterclockwise, push it inward until
it snaps into place.
Do not leave the main switch in this
position for an extended period of
time because the battery may discharge.
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INSTRUMENT AND CONTROL FUNCTIONS
EAU00063
1 2
3
High beam indicator light “&”
This indicator comes on when the
headlight high beam is used.
4
1
.
1.00
EAU03125*
Turn indicator lights “4”/“6”
The corresponding indicator flashes
when the turn signal switch is moved
to the left or right.
0.0
1.
2.
3.
4.
Oil change indicator light “7”
High beam indicator light “&”
Left turn indicator light “4”
Right turn indicator light “6”
2
3
4
5
EAU00056
Indicator lights
6
EAU00078
Oil change indicator light “7”
When this indicator light comes on,
the engine oil should be changed. It
will come on at the initial 1,000 km
and every 3,000 km thereafter. (Refer
to “Engine oil replacement” for resetting procedures.)
The oil change indicator light circuit
can be checked by the procedure on
page 3-3.
7
8
9
3-2
5GM-9-E0 4/13/0 9:05 PM Page 18
INSTRUMENT AND CONTROL FUNCTIONS
EAU00076
Oil change indicator light circuit check
1
2
Turn the main switch to “ON”.
Turn the engine stop switch to “#”.
3
4
5
Indicator light does
not come on.
Indicator light comes
on for a few seconds
and then goes off.
6
7
8
Ask a Yamaha dealer
to inspect electrical circuit.
Electrical circuit is OK.
Go ahead with riding.
9
3-3
5GM-9-E0 4/13/0 9:05 PM Page 19
INSTRUMENT AND CONTROL FUNCTIONS
1
2
Use the trip meter together with the
fuel gauge to estimate how far you
can ride on a tank of fuel. This information will enable you to plan fuel
stops in the future.
3
.
1.00
0.0
To reset the trip odometer to “0.0”,
set the display to the “TRIP” mode.
Then, push the “TRIP” reset button
for at least one second.
1. Speedometer
2. Digital odometer/trip odometer
3. Reset button
EAU00108
Diagnosis device
This model is equipped with a diagnosis device for the oil change indicator light circuit and the speedometer.
If some trouble should occur in the
circuit or the speedometer, the oil
change indicator light will flash. In
this case, take your scooter to a
Yamaha dealer for repair.
NOTE:
The oil change indicator light may
flash when accelerating the engine
while the scooter is on its centerstand, but this is normal.
EAU01586
Speedometer
The speedometer shows riding
speed. This speedometer is equipped
with a digital odometer and a trip
odometer.
Pushing the “TRIP” reset button will
change the display from one to the
other.
When set to “ODO”, the display indicates the scooter’s total mileage.
When set to “TRIP”, the display indicates the scooter’s mileage since the
trip odometer was last reset.
1
2
3
4
5
6
7
8
9
3-4
5GM-9-E0 4/13/0 9:05 PM Page 20
INSTRUMENT AND CONTROL FUNCTIONS
EAU00109
2
Antitheft alarm (optional)
1
1
An antitheft alarm can be equipped to
this scooter. Consult your Yamaha
dealer to obtain and install the alarm.
1
2
3
4
1. Fuel gauge
EAU00110
EAU03124*
Fuel gauge
5
6
7
1. Coolant temperature gauge
2. Red mark
This model is equipped with an electric fuel gauge so the rider can monitor the fuel level in the fuel tank.
When the needle indicates “E”
(Empty), about 1.0 L remain in the
fuel tank.
8
Coolant temperature gauge
This gauge indicates the coolant temperature when the main switch is on.
The engine operating temperature
will vary with changes in weather and
engine load. If the needle points to
the red mark, stop your scooter and
let the engine cool. (See page
6-15 for details.)
9
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EC000002
When the engine is overheated, do
not continue riding.
3-5
5GM-9-E0 4/13/0 9:05 PM Page 21
INSTRUMENT AND CONTROL FUNCTIONS
1 2
1
NOTE:
When setting the clock after its power
source is cut by a removed battery,
etc., or when pushing the “h” and “m”
button simultaneously, first set the
time for 1:00 AM, then, go on to set it
for the correct time.
3
1..00
1
2
3
3
4
1. Hour button “h”
2. Minute button “m”
3. Digital clock
1.
2.
3.
4.
EAU03089*
Digital clock
2
Pass switch “&”
Dimmer switch
Turn signal switch
Horn switch “*”
4
EAU00118
5
Handlebar switches
This digital clock shows the time
regardless of the main switch position.
6
EAU00119
Pass switch “&”
Press the switch to operate the passing light.
To set the clock
1. Turn the key to “ON”.
2. The time (hour) setting can be
made by pushing or holding the
“h” button.
3. The time (minute) setting can be
made by pushing or holding the
“m” button.
7
8
EAU00121
Dimmer switch
Turn the switch to “&” for the high
beam and to “%” for the low beam.
3-6
9
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INSTRUMENT AND CONTROL FUNCTIONS
1
1
2
2
3
3
4
5
6
7
8
9
1
2
3
4
1.
2.
3.
4.
Pass switch “&”
Dimmer switch
Turn signal switch
Horn switch “*”
1. Engine stop switch
2. Light switch
3. Start switch “,”
EAU00135
EAU00127
Turn signal switch
To signal a right-hand turn, push the
switch to “6”. To signal a left-hand
turn, push the switch to “4”. Once
the switch is released it will return to
the center position. To cancel the signal, push the switch in after it has
returned to the center position.
Light switch
Turning the light switch to “'”
turns on the auxiliary light, meter
lights, taillight and licence light.
Turning the light switch to “:” turns
the headlight on also.
EAU00129
Horn switch “*”
Press the switch to sound the horn.
3-7
5GM-9-E0 4/13/0 9:05 PM Page 23
INSTRUMENT AND CONTROL FUNCTIONS
EAU00136
Headlight beam variation
Left
1
2
3 : High beam light on
' : Auxiliary light on
Right
Aux
%
2
1
'
&
1
3
'
%
1
2
'
&
3
1
'
Bulb to be used
Halogen
bulb
12V
55W
Halogen
bulb
12V
60/55W
2 : Low beam light on
1 : Light off
Destination
12V
60/55W
12V
55W
Germany, Belgium, Switzerland, Spain
France, Greece, Italy, Netherlands,
Norway, Portugal, Sweden
England
NOTE:
Right and left directions are those assumed from the position of a person facing the front of the scooter.
1
2
3
4
5
6
7
8
9
3-8
5GM-9-E0 4/13/0 9:05 PM Page 24
INSTRUMENT AND CONTROL FUNCTIONS
EAU00143
Start switch “,”
The starter motor cranks the engine
when pushing the start switch.
1
1
1
2
2
3
3
4
EC000005
cC
See starting instructions prior to
starting the engine.
1. Engine stop switch
2. Light switch
3. Start switch “,”
1. Front brake lever
EAU00158
Front brake lever
EAU00138
5
6
7
8
9
The front brake lever is located on
the right handlebar. Pull it toward the
handlebar to apply the front brake.
Engine stop switch
The engine stop switch is a safety
device for use in an emergency such
as when the scooter overturns or if
trouble occurs in the throttle system.
Turn the switch to “#” to start the
engine.
In case of emergency, turn the switch
to “$” to stop the engine.
3-9
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INSTRUMENT AND CONTROL FUNCTIONS
1
1
1
1
2
2
3
1. Rear brake lever
EAU00163
Rear brake lever
The rear brake lever is located on the
left handlebar. Pull it toward the handlebar to apply the rear brake.
1. Lid
2. Lever
1. Fuel tank cap
EAU03090*
Fuel tank cap
The fuel tank cap is located under the
lid in front of the seat.
To open the lid, slide the lever forward and then pull the lever up.
To open the fuel tank cap, insert the
key into the lock and turn it clockwise.
4
5
6
7
8
9
3-10
5GM-9-E0 4/13/0 9:05 PM Page 26
INSTRUMENT AND CONTROL FUNCTIONS
EAU00185
cC
Always wipe off spilled fuel immediately with a dry and clean soft
cloth. Fuel may deteriorate painted
surfaces or plastic parts.
1
1
2
3
4
5
6
7
8
9
2
1
EAU00191*
1. Match marks
To close the cap, align the match
marks and push down on the cap.
Then, turn the key to the original
position and remove it. Close the lid.
w
EWA00028*
Be sure the cap is properly
installed and locked in place
before riding the scooter.
1. Filler tube
2. Fuel level
EAU01183
Fuel
Make sure there is sufficient fuel in
the tank. Fill the fuel tank to the bottom of the filler tube as shown in the
illustration.
EW000130
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Do not overfill the fuel tank. Avoid
spilling fuel on the hot engine. Do
not fill the fuel tank above the bottom of the filler tube or it may
overflow when the fuel heats up
later and expands.
3-11
Recommended fuel:
Regular unleaded gasoline
with a research octane
number of 91 or higher.
Fuel tank capacity:
Total amount:
12 L
NOTE:
If knocking or pinging occurs, use a
different brand of gasoline or higher
octane grade.
5GM-9-E0 4/13/0 9:05 PM Page 27
INSTRUMENT AND CONTROL FUNCTIONS
EC000114
This scooter is equipped with a catalytic converter in the muffler.
The following must be observed to
prevent a fire hazard or other damages.
8 Use only unleaded gasoline.
Use of leaded gasoline will
cause unrepairable damage to
the catalytic converter.
8 Never park this scooter in an
area that would cause a fire
hazard such as grass or other
materials that may easily burn.
8 Do not allow the engine to idle
for very long.
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EW000128
The exhaust system is hot during
and directly after engine operation.
Make sure the exhaust system has
cooled down before making any
adjustment to or lubricating the
scooter.
OFF
ON
1
OPEN
PUSH
2
LOCK
N
cC
PUSH
P
O
EAU03098*
Catalyzer
IG N
I TI
3
EAU03091*
4
Rider seat
To open
Insert the key into the main switch
and turn it counterclockwise. Do not
push inward when turning the key.
5
6
7
To close
Push the rider seat downward to the
original position and remove the key
from the main switch.
3-12
8
9
5GM-9-E0 4/13/0 9:05 PM Page 28
INSTRUMENT AND CONTROL FUNCTIONS
1
2
2
1
2
3
1
1. Rider seat
4
5
6
7
NOTE:
8 Place the scooter on the centerstand before opening the rider
seat.
8 Make sure the rider seat is
securely closed before riding the
scooter.
EAU03096*
Rider seat adjustment
The rider seat can be adjusted to
change the riding position.
8
9
3-13
1
1. Bolt (×4)
2. Collar (×4)
To adjust, open the rider seat and
remove the bolts and collars. Slide
the seat forward or backward to the
desired position. Install the collars
and tighten the bolts securely. Then
close the seat.
5GM-9-E0 4/13/0 9:05 PM Page 29
INSTRUMENT AND CONTROL FUNCTIONS
Compartment A
Compartment B
1
1
2
2
1
1. Button
2. Lid
3
1. Lever
2. Lid
EAU03110*
Storage compartments
Front storage compartment A
To open the storage compartment
when it is locked, insert the key, turn
it counterclockwise, grasp the lock
while pushing the button in.
To open the storage compartment
when it is unlocked, simply grasp the
lock while pushing the button in.
To lock the storage compartment,
push the lid into the original position.
Insert the key and turn it clockwise.
Then remove the key.
2
4
Front storage compartment B
To open the storage compartment,
slide the lever up and pull on the
lever.
To close the storage compartment,
push the lid into the original position.
Rear storage compartment
Two helmets can be stored in the
compartment under the seats. When
the rider seat is opened, the compartment light will come on. (See page
3-12 for rider seat opening and closing procedures.)
5
6
7
EWA00029*
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8
Do not store heavy items in this
compartment.
3-14
9
5GM-9-E0 4/13/0 9:05 PM Page 30
INSTRUMENT AND CONTROL FUNCTIONS
cC
1
2
3
4
5
6
7
8
9
ECA00051*
Do not leave the rider seat open
for an extended period of time as
the light may cause the battery to
discharge.
w
Standard
Soft
1
a
1
2
3
4
Hard
5
6
7
2
w
b
1. Spring preload adjusting ring
2. Position indicator
EAU00300
Rear shock absorber
adjustment
Each shock absorber is equipped
with a spring preload adjusting ring.
Adjust spring preload as follows.
Turn the adjusting ring in direction a
to increase spring preload and in
direction b to decrease spring preload. Make sure that the appropriate
notch in the adjusting ring is aligned
with the position indicator on the rear
shock absorber.
3-15
EW000040
Always
adjust
each
shock
absorber to the same setting.
Uneven adjustment can cause
poor handling and loss of stability.
EWA00030*
Do not exceed the loading limits:
Front storage compartment A: 2 kg
Rear storage compartment: 5 kg
Adjusting
Position
5GM-9-E0 4/13/0 9:05 PM Page 31
INSTRUMENT AND CONTROL FUNCTIONS
EAU03092*
EAU00330
Carrier (optional)
Sidestand
An optional carrier can be obtained
and installed at a Yamaha dealer for
adding cargo or accessories to this
scooter.
This model is equipped with an ignition circuit cut-off system. The scooter must not be ridden when the sidestand is down. The sidestand is
located on the left side of the frame.
(Refer to page 3-17 for an explanation of this system.)
w
EW000044
This scooter must not be operated
with the sidestand in the down
position. If the stand is not properly retracted, it could contact the
ground and distract the operator,
resulting in a possible loss of control. Yamaha has designed into
this scooter a lockout system to
assist the operator in fulfilling the
responsibility of retracting the
sidestand. Please check carefully
the operating instructions listed
below and if there is any indication
of a malfunction, return the scooter to a Yamaha dealer immediately
for repair.
1
2
3
4
5
6
7
8
9
3-16
5GM-9-E0 4/13/0 9:05 PM Page 32
INSTRUMENT AND CONTROL FUNCTIONS
1
Turn the main switch to “ON” and
the engine stop switch to “#”.
1
Put the sidestand up.
2
Push the start switch while applying
either of the brake levers.
The engine will start.
3
4
1. Sidestand switch
EAU00337
5
Sidestand switch operation
check
Put the sidestand down.
6
Check the operation of the sidestand
switch against the information below.
If the engine stalls:
7
8
9
w
EW000046
8 Be sure to use the centerstand
during this inspection.
8 If improper operation is noted,
consult a Yamaha dealer.
The sidestand switch is OK.
EW000045
w
If improper operation is noted,
consult a Yamaha dealer immediately.
3-17
5GM-9-E0 4/13/0 9:05 PM Page 33
PRE-OPERATION CHECKS
Pre-operation check list ......................................................................4-1
4
5GM-9-E0 4/13/0 9:05 PM Page 34
EAU01114
PRE-OPERATION CHECKS
1
Owners are personally responsible for their vehicle’s condition. Your scooter’s vital functions can start to deteriorate
quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid
leak or loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual inspection, you check the following points before each ride.
EAU00340
PRE-OPERATION CHECK LIST
2
ITEM
3
Front brake
Rear brake
4
Engine oil
6
Final gear oil
Throttle grip and
housing
Wheels and tires
7
Lights, signals and switches
5
Chassis fasteners
8
9
9
9
9
9
9
9
9
9
9
9
9
9
CHECKS
Check operation, free play, fluid level and vehicle for fluid leakage.
Fill with DOT 4 brake fluid if necessary.
Check operation, free play, fluid level and vehicle for fluid leakage.
Fill with DOT 4 brake fluid if necessary.
Check oil level
Fill with oil if necessary.
Check vehicle for leakage.
Check for smooth operation.
Lubricate if necessary.
Check tire pressure, wear and damage.
Make sure that all nuts, bolts, and screws are properly tightened.
Tighten if necessary.
Check for proper operation.
PAGE
3-9, 6-20 ~ 6-23
3-10, 6-20 ~ 6-23
6-11 ~ 6-13
6-14
—
6-18 ~ 6-20
—
3-6 ~ 3-9, 6-28 ~ 6-32
NOTE:
Pre-operation checks should be made each time the scooter 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.
9
w
If any item in the Pre-Operation Check is not working properly, have it inspected and repaired before operating
the scooter.
4-1
5GM-9-E0 4/13/0 9:05 PM Page 35
OPERATION AND IMPORTANT RIDING POINTS
Starting a cold engine.........................................................................5-1
Starting off ..........................................................................................5-2
Acceleration........................................................................................5-2
Braking ...............................................................................................5-2
Tips for reducing fuel consumption.....................................................5-3
Engine break-in ..................................................................................5-3
Parking ...............................................................................................5-4
5
5GM-9-E0 4/13/0 9:05 PM Page 36
OPERATION AND IMPORTANT RIDING POINTS
w
1
2
3
4
5
6
7
8
9
EAU01118
1. Before riding this scooter,
become thoroughly familiar
with all operating controls and
their functions. Consult a
Yamaha dealer regarding any
control or function that you do
not thoroughly understand.
2. Never start your engine or let
it run for any length of time in
a closed area. The exhaust
fumes are poisonous and can
cause loss of consciousness
and death within a short time.
Always operate your scooter
in an area with adequate ventilation.
3. For safety, be sure to start the
engine with the centerstand
down.
EAU00419
Starting a cold engine
NOTE:
This scooter is equipped with an ignition circuit cut-off switch. The scooter
must not be ridden with the sidestand
down.
1. Turn the main switch to “ON” and
the engine stop switch to “#”.
2. Completely close the throttle
grip.
3. Apply either brake and push the
start switch to start the engine.
5-1
EAU00372
NOTE:
8 If the engine fails to start, release
the start switch, wait a few seconds, then try again. Each
attempt should be as short as
possible to preserve the battery.
Do not crank the engine more
than 10 seconds on any one
attempt.
8 For maximum engine life, never
accelerate hard with a cold
engine!
5GM-9-E0 4/13/0 9:05 PM Page 37
OPERATION AND IMPORTANT RIDING POINTS
1
1
2
3
1. Grab bar
EAU00433
EAU00434
Starting off
Acceleration
After warming up the engine:
1. Apply the rear brake lever with
your left hand and hold the grab
bar with you right hand. Then
push the scooter off the centerstand.
2. Sit astride the seat and adjust
the rear view mirrors.
3. Check the oncoming traffic and
use a turn signal.
4. Turn the throttle grip on the right
handlebar slowly and you will
start off. Remember to turn off
the turn signal.
The speed can be adjusted by opening and closing the throttle grip.
Turning it toward you increases the
speed, and turning it in the opposite
direction decreases the speed.
EAU00435
4
Braking
1. Close the throttle grip.
2. Apply both front and rear brakes
simultaneously with light pressure and increase the pressure
slowly.
5
6
7
8
9
5-2
5GM-9-E0 4/13/0 9:05 PM Page 38
OPERATION AND IMPORTANT RIDING POINTS
w
1
2
3
4
5
6
7
8
EW000057
8 Avoid hard or sudden braking.
It may cause the scooter to
skid or overturn.
8 Be sure to apply the brake
carefully if leaning over to one
side. Improper braking could
lead to a skid.
8 Street car rails, metal plates
on road construction sites,
and man-hole covers become
particularly slippery when they
get wet. Cross them slowly
and cautiously.
8 Braking on a wet road is very
difficult.
8 Braking on a hill can be difficult. Proceed slowly when riding downhill.
EAU03093*
Tips for reducing fuel
consumption
Your scooter’s fuel consumption
depends to a large extent on your riding style. The following tips can help
reduce fuel consumption:
8 Warm up the engine before riding.
8 Avoid high engine speeds during
acceleration.
8 Avoid high engine speeds with
no load on the engine.
8 Turn off the engine instead of letting it idle for an extended length
of time, i.e. in traffic jams, at traffic lights or railroad crossings.
9
5-3
EAU01128
Engine break-in
There is never a more important period in the life of your scooter than the
period
between
zero
and
1,600 km. For this reason we ask that
you carefully read the following material. Because the engine is brand
new, you must 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 which might result in
excessive heating of the engine,
must be avoided.
5GM-9-E0 4/13/0 9:05 PM Page 39
OPERATION AND IMPORTANT RIDING POINTS
EAU03123*
0 ~ 1,000 km
Avoid operation above 1/3 throttle.
1,000 ~ 1,600 km
Avoid cruising speeds in excess of
1/2 throttle.
cC
EAU00461
1,600 km and beyond
Proceed with normal riding.
Parking
EC000049
cC
If any engine trouble should occur
during the break-in period, consult
a Yamaha dealer immediately.
ECA00054*
After 1,000 km of operation, be
sure to replace the engine oil and
final gear oil.
When parking the scooter, stop the
engine and remove the ignition key.
w
2
The muffler and exhaust pipe are
hot. Park the scooter in a place
where pedestrians or children are
not likely to touch the scooter. Do
not park the scooter on a slope or
soft ground; the scooter may overturn.
cC
1
EW000059
EC000062
Never park this scooter in an area
that would cause a fire hazzard
such as grass or other materials
that may easily burn.
3
4
5
6
7
8
9
5-4
5GM-9-E0 4/13/0 9:05 PM Page 40
5GM-9-E0 4/13/0 9:09 PM Page 41
PERIODIC MAINTENANCE AND MINOR REPAIR
Tool kit ....................................................................6-1
Periodic maintenance and lubrication .....................6-3
Panel removal and installation ................................6-6
Panel A ...................................................................6-6
Panel B ...................................................................6-8
Panel C ...................................................................6-8
Spark plug.............................................................6-10
Engine oil ..............................................................6-11
Final gear oil replacement.....................................6-14
Coolant..................................................................6-15
Air filter and V-belt case filter cleaning..................6-16
Air flow louver .......................................................6-18
Tires ......................................................................6-18
Wheels ..................................................................6-20
Brake lever free play adjustment ..........................6-20
Checking the front and rear brake pads................6-21
Inspecting the brake fluid level..............................6-22
Brake fluid replacement ........................................6-23
Cable inspection and lubrication ...........................6-23
Brake lever lubrication ..........................................6-23
Center and sidestand lubrication ..........................6-24
Front fork inspection .............................................6-24
Steering inspection ...............................................6-25
Wheel bearings .....................................................6-25
Battery cover removal ...........................................6-26
Battery...................................................................6-26
Fuse replacement .................................................6-27
Headlight bulb replacement ..................................6-28
Tail/brake light bulb replacement ..........................6-30
Front turn signal light bulb replacement................6-30
Rear turn signal light bulb replacement ................6-31
License light bulb replacement .............................6-32
Troubleshooting ....................................................6-33
Troubleshooting chart ...........................................6-34
6
5GM-9-E0 4/13/0 9:09 PM Page 42
EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00464
1
2
3
4
5
6
7
8
9
Periodic inspection, adjustment and
lubrication will keep your scooter in
the safest and most efficient condition possible. Safety is an obligation
of the scooter owner. The maintenance and lubrication schedule chart
should be considered strictly as a
guide to general maintenance and
lubrication intervals.
YOU MUST TAKE INTO CONSIDERATION THAT WEATHER, TERRAIN,
GEOGRAPHICAL LOCATIONS, AND
A VARIETY OF INDIVIDUAL USES
ALL TEND TO DEMAND THAT
EACH OWNER ALTER THIS TIME
SCHEDULE TO SHORTER INTERVALS TO MATCH THE ENVIRONMENT. The most important points of
scooter inspection, adjustment, and
lubrication are explained in the following pages.
EW000060
w
If you are not familiar with scooter
service, this work should be done
by a Yamaha dealer.
1
EAU00466
w
This scooter is designed for use
on paved road surface only. If this
scooter is operated in abnormally
dusty, muddy or wet conditions,
the air filter should be cleaned or
replaced
more
frequently.
Otherwise, rapid engine wear may
result. Consult a Yamaha dealer
for proper maintenance intervals.
6-1
1. Tool kit
EAU01129
Tool kit
The tool kit is located inside of the
storage compartment. (See page
3-14 for compartment opening procedures.) The tools provided in the
owner’s tool kit are to assist you in
the performance of periodic maintenance. However, some other tools
such as a torque wrench are also
necessary to perform the maintenance correctly.
The service information included in
this manual is intended to provide
you, the owner, with the necessary
information for completing some of
your own preventive maintenance
and minor repairs.
5GM-9-E0 4/13/0 9:09 PM Page 43
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
If you do not have necessary tools
required during a service operation,
take your scooter to a Yamaha dealer
for service.
w
1
2
EW000062
3
Modifications to this scooter not
approved by Yamaha may cause
loss of performance, excessive
emissions, and render it unsafe for
use. Consult a Yamaha dealer
before attempting any changes.
4
5
6
7
8
9
6-2
5GM-9-E0 4/13/0 9:09 PM Page 44
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00473
PERIODIC MAINTENANCE AND LUBRICATION
No.
ITEM
CHECKS AND MAINTENANCE JOB
1
2
3
4
1 * Fuel line
9 Check fuel hoses and vacuum hose for cracks or damage.
9 Replace if necessary.
2
Fuel filter
9 Check condition.
9 Replace if necessary.
3
Spark plug
9 Check condition.
9 Clean, regap or replace if necessary.
√
ANNUAL
CHECK
√
√
√
9 Check valve clearance.
9 Adjust if necessary.
5
Air filter
9 Clean or replace if necessary.
√
6
V-belt case air filter
9 Clean or replace if necessary.
√
√
7 * Front brake
9 Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)
9 Correct accordingly.
9 Replace brake pads if necessary.
√
√
√
8 * Rear brake
9 Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)
9 Correct accordingly.
9 Replace brake pads if necessary.
√
√
√
9 * Brake hoses
9 Check for cracks or damage.
9 Replace if necessary.
√
√
10 * Wheels
9 Check balance, runout and for damage.
9 Rebalance or replace if necessary.
√
11 * Tires
9 Check tread depth and for damage.
9 Replace if necessary.
9 Check air pressure.
9 Correct if necessary.
√
12 * Wheel bearings
9 Check bearing for looseness or damage.
9 Replace if necessary.
√
6
8
EVERY
10,000 km 20,000 km
4 * Valves
5
7
Initial
(1,000 km)
9
6-3
5GM-9-E0 4/13/0 9:09 PM Page 45
PERIODIC MAINTENANCE AND MINOR REPAIR
No.
ITEM
13 * Steering bearings
CHECKS AND MAINTENANCE JOB
9 Check bearing play and steering for roughness.
9 Correct accordingly.
Initial
(1,000 km)
√
EVERY
10,000 km 20,000 km
ANNUAL
CHECK
√
1
√
9 Lubricate with lithium soap base grease.
14 * Chassis fasteners
9 Make sure that all nuts, bolts and screws are properly tightened.
9 Tighten if necessary.
√
√
15
9 Check operation.
9 Lubricate and repair if necessary.
√
√
√
√
Sidestand/centerstand
16 * Sidestand switch
9 Check operation.
9 Replace if necessary.
17 * Front fork
9 Check operation and for oil leakage.
9 Correct accordingly.
√
9 Check operation and shock absorbers for oil leakage.
9 Replace shock absorber assembly if necessary.
√
18 *
Rear shock absorber
assemblies
√
9 Check engine idling speed and starter operation.
9 Adjust if necessary.
√
20
9 Check oil level and vehicle for oil leakage.
9 Correct if necessary.
9 Change. (Warm engine before draining.)
√
Replace every 3,000 km
9 Clean or replace if necessary.
√
Clean or replace every 6,000 km
21 * Engine oil strainer
22 * Cooling system
23
Final gear oil
24 * V-belt
9 Check coolant level and vehicle for coolant leakage.
9 Correct if necessary.
√
9 Check oil level and vehicle for oil leakage.
9 Change oil.
√
9 Replace.
6-4
√
√
9 Change coolant.
3
4
19 * Carburetor
Engine oil
2
5
6
7
√
√
8
√
9
√
5GM-9-E0 4/13/0 9:09 PM Page 46
PERIODIC MAINTENANCE AND MINOR REPAIR
No.
ITEM
25 * Front/Rear brake switch
1
26
CHECKS AND MAINTENANCE JOB
9 Check operation.
9 Adjust or replace if necessary.
Initial
(1,000 km)
EVERY
10,000 km 20,000 km
√
Moving parts and cables 9 Lubricate if necessary.
9 Check all lights, signals and switches function.
9 Correct if necessary.
9 Adjust headlight beam if necessary.
√
ANNUAL
CHECK
√
√
√
√
√
√
2
27 * Electrical components
3
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
4
NOTE:
8 The annual checks must be performed every year, except if a 10,000 km or 20,000 km maintenance is performed
instead.
8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8 Hydraulic brake service
8 Regularly check and, if necessary, correct the brake fluid level.
8 Every two years replace the internal components of the brake master cylinder and caliper, and change the brake
fluid.
8 Replace the brake hoses every four years and if cracked or damaged.
EAU03206
5
6
7
8
9
6-5
5GM-9-E0 4/13/0 9:09 PM Page 47
PERIODIC MAINTENANCE AND MINOR REPAIR
1
1
1
2
1
1. Panel A
1. Panel C
1. Panel B
EAU01122
Panel removal and
installation
3
4
5
The panels illustrated need to be
removed to perform some of the
maintenance described in this chapter.
Refer to this section each time a
panel has to be removed or reinstalled.
6
7
8
9
6-6
5GM-9-E0 4/13/0 9:09 PM Page 48
PERIODIC MAINTENANCE AND MINOR REPAIR
2
1
1
2
3
4
1
1
1. Screw (×2)
EAU03114*
Panel A
5
2. Pull the panel back as shown.
To remove
1. Remove the screws.
6
7
8
9
6-7
1. Tab (×2)
2. Slot (×2)
To install
1. Insert the tabs on the panel into
the slots as shown, and then
push the panel in until it snaps
into place.
2. Install the screws.
5GM-9-E0 4/13/0 9:09 PM Page 49
PERIODIC MAINTENANCE AND MINOR REPAIR
1
1
2
2
3
1. Bolt (×2)
2. Panel B
EAU03121*
Panel B
To remove
Remove the bolts, and then pull the
panel out as shown.
To install
Place the panel in the original position, and then install the bolts.
EAU03122*
4
Panel C
To remove
1. Pull up the left floorboard mat as
shown.
5
6
7
8
9
6-8
5GM-9-E0 4/13/0 9:09 PM Page 50
PERIODIC MAINTENANCE AND MINOR REPAIR
1
1
2
1
3
2
4
1. Screw (×4)
2. Panel C
2. Remove the panel screws.
3. Pull the panel out as shown.
5
6
7
8
9
6-9
To install
1. Insert the tabs on the panel into
the slots as shown.
2. Install the panel screws.
5GM-9-E0 4/13/0 9:09 PM Page 51
PERIODIC MAINTENANCE AND MINOR REPAIR
1
1
1. Spark plug cap
1. Spark plug wrench
EAU01833
Spark plug
Removal
1. Remove the spark plug cap.
2. Use the spark plug wrench in the
tool kit to remove the spark plug
as shown.
Inspection
The spark plug is an important
engine component and is easy to
inspect. The condition of the spark
plug can indicate the condition of the
engine.
The ideal color on the white insulator
around the center electrode is a
medium-to-light tan color for a scooter that is being ridden normally.
Do not attempt to diagnose such
problems yourself. Instead, take the
scooter to a Yamaha dealer. You
should periodically remove and
inspect the spark plug because heat
and deposits will cause any spark
plug to slowly break down and erode.
If electrode erosion becomes excessive, or if carbon and other deposits
are excessive, you should replace
the spark plug with the specified plug.
Specified spark plug:
DR8EA (NGK)
6-10
1
2
3
4
5
6
7
8
9
5GM-9-E0 4/13/0 9:09 PM Page 52
PERIODIC MAINTENANCE AND MINOR REPAIR
Tightening torque:
Spark plug:
17.5 Nm (1.75 m0kg)
1
2
1
3
4
5
6
7
8
9
1. Spark plug gap
Installation
1. Measure the electrode gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
NOTE:
If a torque wrench is not available
when you are installing a spark plug,
a good estimate of the correct torque
is 1/4 to 1/2 turn past finger tight.
Have the spark plug tightened to the
specified torque as soon as possible.
1
2
1
1. Oil filler cap
2. Dipstick
EAU03119*
Engine oil
4. Install the spark plug cap.
Spark plug gap:
0.6 ~ 0.7 mm
Oil level measurement
1. Place the scooter on the centerstand. Warm up the engine for
several minutes.
NOTE:
8 Be sure the scooter is positioned
straight up when checking the oil
level. A slight tilt toward the side
can result in false readings.
8 When adding oil, be careful not
to overfill the engine; the oil level
rises faster starting from the half
level portion on the dipstick.
2. Clean the gasket surface. Wipe
off any grime from the threads.
3. Install the spark plug and tighten
it to the specified torque.
6-11
5GM-9-E0 4/13/0 9:09 PM Page 53
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
1
1
2
2
1
1. Maximum level mark
2. Minimum level mark
2. Stop the engine and remove the
oil filler cap.
NOTE:
Wait a few minutes until the oil settles
before checking.
3. Wipe the oil off the dipstick.
Insert the dipstick back into the
engine oil filler hole, but do not
screw it in. Then pull out the dipstick again.
The oil level should be between
the minimum and maximum
marks on the dipstick. If the level
is low, add sufficient oil through
the engine oil filler hole to reach
the specified level.
1. Drain bolt
Engine oil replacement
1. Warm up the engine for a few
minutes.
2. Stop the engine. Place an oil pan
under the engine to catch the oil
and remove the oil filler cap.
3. Remove the drain bolt and drain
the oil.
3
1. Drain bolt
2. Washer
4. Check the washer and replace it
if damaged.
5. Install the washer and drain bolt,
and then tighten the drain bolt to
the specified torque.
Tightening torque:
Drain bolt:
20 Nm (2.0 m0kg)
NOTE:
Make sure the washer is seated
properly.
6-12
4
5
6
7
8
9
5GM-9-E0 4/13/0 9:09 PM Page 54
PERIODIC MAINTENANCE AND MINOR REPAIR
6. Fill the engine with oil and install
the oil filler cap.
1
2
3
4
5
6
7
8
9
1
Recommended oil:
See page 8-1.
Oil quantity:
Total amount: 1.4 L
Periodic oil change: 1.2 L
cC
EC000030
8 Do not put in any chemical
additives or use oils with a
grade of CD or higher. Also, be
sure not to use oils labeled
“ENERGY CONSERVING II” or
higher.
8 Be sure no foreign material
enters the crankcase.
1. Oil change indicator light reset button
Resetting the oil change indicator
light
1. Turn the key to “ON”.
2. Push and hold in the reset button
for 2 ~ 5 seconds.
3. Release the reset button and the
oil change indicator light will go
off.
7. Start the engine and warm it up
for a few minutes. While warming
up, check for oil leakage. If oil
leakage is found, stop the engine
immediately and check for the
cause.
6-13
NOTE:
If the oil is changed before the oil
change indicator light comes on (i.e.
before the 3,000-km oil change interval is reached), be sure to reset it
after changing the oil, so that it will
come on at the correct time to indicate the next 3,000-km oil replacement.
To reset the oil change indicator light
before it comes on, follow steps 1
and 2. Then, release the reset button
and the oil change indicator light will
come on for 1.4 seconds. If it does
not come on for 1.4 seconds, repeat
the procedure.
5GM-9-E0 4/13/0 9:09 PM Page 55
PERIODIC MAINTENANCE AND MINOR REPAIR
6. Install the oil filler cap.
7. After replacing the final gear oil,
be sure to check for oil leakage.
1
1
2
1
1. Final gear oil filler cap
1. Drain bolt
EAU03120*
Final gear oil replacement
1. Put the scooter on the centerstand.
2. Place an oil pan under the final
gear case to catch the oil.
3. Remove the oil filler cap and the
drain bolt to drain the oil.
4. Install and tighten the drain bolt
to the specified torque.
Tightening torque:
Drain bolt:
22 Nm (2.2 m0kg)
3
4
5. Fill the gear case with the recommended oil.
Recommended final gear oil:
SAE 10W30 type SE motor oil
Final gear case capacity:
0.25 L
5
6
7
EW000066
w
8
Do not let foreign material enter
the final gear case. Be sure oil
does not get on the tire or wheel.
6-14
9
5GM-9-E0 4/13/0 9:09 PM Page 56
PERIODIC MAINTENANCE AND MINOR REPAIR
Reservoir tank capacity:
0.4 L
1
1
1
NOTE:
The radiator fan operation is completely automatic. It is switched on or
off according to the coolant temperature in the radiator.
2
2
3
4
1. Maximum level mark
2. Minimum level mark
1. Coolant reservoir tank cap
EAU01587
5
6
7
8
9
Coolant
The coolant reservoir tank is located
under the battery cover. (See page
6-26 for battery cover removal procedures.)
Check the coolant level in the reservoir tank when the engine is cold.
The coolant level will vary with engine
temperature. The coolant level is satisfactory if it is between the minimum
and maximum marks on the tank. If
the coolant level is at or below the
minimum mark, fill with tap water (soft
water) to bring the level up to the
maximum mark.
Have a Yamaha dealer change the
coolant every two years.
If your scooter overheats, see page
6-35 for details.
EW000067
w
Do not remove the radiator cap
when the engine is hot.
EC000080
cC
Hard water or salt water is harmful
to the engine. You may use distilled water if you can’t get soft
water.
6-15
5GM-9-E0 4/13/0 9:09 PM Page 57
PERIODIC MAINTENANCE AND MINOR REPAIR
2
1
1
1
2
3
2
1. Air filter case cover
2. Screw (×5)
1. Air filter element
EAU03113*
Air filter and V-belt case air
filter cleaning
The air filter and V-belt case air filter
should be cleaned at the specified
intervals.
They should be cleaned more frequently if you are riding in unusually
wet or dusty areas.
1. Place the scooter on the centerstand.
2. Remove panel C. (See page 6-8
for panel removal and installation
procedures.)
3. Remove the air filter case cover
by removing the screws.
4
4. Remove the air filter element and
wash it gently, but thoroughly in
solvent. If the air filter element is
damaged, replace it.
5. Squeeze out the excess solvent
and allow it to dry.
6. Apply oil to the entire surface of
the air filter element and
squeeze out the excess oil. It
should be damp, but not dripping.
Recommended oil:
Engine oil
7. Install the air filter element and
the air filter case cover.
6-16
5
6
7
8
9
5GM-9-E0 4/13/0 9:09 PM Page 58
PERIODIC MAINTENANCE AND MINOR REPAIR
cC
1
8 Make sure both filters are
properly seated in their cases.
8 The engine should never be
run
without
the
filters
installed.
1
2
2
1
3
11. Install panel C.
4
5
6
7
8
9
1. V-belt case air filter cover
2. Screw (×3)
8. Remove the V-belt case air filter
cover by removing the screws.
EC000092
1. V-belt case air filter
9. Remove the V-belt case air filter
element and blow out the dirt
with compressed air from the
inner side of the V-belt case air
filter element. If the V-belt case
air filter element is damaged,
replace it.
10. Install the V-belt case air filter
element with the colored side
facing outward, and then install
the V-belt case air filter cover.
6-17
5GM-9-E0 4/13/0 9:09 PM Page 59
PERIODIC MAINTENANCE AND MINOR REPAIR
2
b
1
a
3
1. Louver
2. Air inlet
3. Lever
EAU00675
EAU03094*
Air flow louver
Opening the air flow louver may help
reduce air turbulence.
To open the air flow louver, move the
lever in direction a.
To close the air flow louver, move the
lever in direction b.
cC
EW000082
w
Tires
To ensure maximum performance,
long service and safe operation, note
the following:
Tire air pressure
Always check and adjust the tire
pressure before operating the scooter.
Tire inflation pressure should be
checked and adjusted when the
temperature of the tire equals the
ambient air temperature. Tire inflation pressure must be adjusted
according to total weight of cargo,
rider, passenger, and accessories
(fairing,
saddlebags,
etc.
if
approved for this model), and vehicle speed.
Maximum load*
Cold tire pressure
187 kg
Front
Rear
Be sure to close the louver when
riding in the rain and when washing the scooter.
6-18
2
3
4
5
6
Up to 90 kg
175 kPa
200 kPa
(1.75 kg/cm2, (2.00 kg/cm2,
1.75 bar)
2.00 bar)
7
90 kg load ~
maximum load*
200 kPa
225 kPa
(2.00 kg/cm2, (2.25 kg/cm2,
2.00 bar)
2.25 bar)
8
* Load is the total weight of cargo, rider, passenger
and accessories.
ECA00049*
1
9
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PERIODIC MAINTENANCE AND MINOR REPAIR
w
1
2
3
4
5
6
7
8
9
FRONT
EW000083
Proper loading of your scooter is
important for several characteristics of your scooter, such as handling, braking, performance and
safety. Do not carry loosely
packed items that can shift.
Securely pack your heaviest items
close to the center of the scooter,
and distribute the weight evenly
from side to side. Properly adjust
the suspension for your load, and
check the condition and pressure
of your tires. NEVER OVERLOAD
YOUR SCOOTER. Make sure the
total weight of the cargo, rider,
passenger, and accessories (fairing, saddlebags, etc. if approved
for this model) does not exceed
the maximum load of the scooter.
Operation of an overloaded scooter could cause tire damage, an
accident, or even injury.
1
Size
Type
INOUE
Manufacturer
110/90-12 64L
MB67
MICHELIN
110/90-12 64L
BOPPER
REAR
2
1. Tread depth
2. Side wall
Size
Type
INOUE
Manufacturer
130/70-12 62L
MB67
MICHELIN
130/70-12 62L
BOPPER
Minimum tire tread
depth (front and rear)
Tire inspection
Always check the tires before operating the scooter. If center tread depth
reaches the limit as shown, if the tire
has a nail or glass fragments in it, or
if the side wall is cracked, contact a
Yamaha dealer immediately and
have the tire replaced.
6-19
1.6 mm
NOTE:
These limits may be different by regulation from country to country. If so,
conform to the limits specified by the
regulations of your own country.
5GM-9-E0 4/13/0 9:09 PM Page 61
PERIODIC MAINTENANCE AND MINOR REPAIR
w
EW000079
Operating the scooter with excessively worn tires decrease riding
stability and can lead to loss of
control. Have excessively worn
tires replaced by a Yamaha dealer
immediately. Brakes, tires, and
related wheel parts replacement
should be left to a Yamaha Service
Technician.
EAU00687
Wheels
To ensure maximum performance,
long service, and safe operation, note
the following:
8 Always inspect the wheels
before a ride. Check for cracks,
bends, or warpage of the wheels.
If any abnormal condition exists
in a wheel, consult a Yamaha
dealer. Do not attempt even
small repairs to the wheel. If a
wheel is deformed or cracked, it
must be replaced.
8 Tires and wheels should be balanced whenever either one is
changed or replaced. Failure to
have a wheel balanced can
result in poor performance,
adverse handling characteristics,
and shortened tire life.
8 Ride at moderate speeds after
changing a tire since the tire surface must first be broken in for it
to develop its optimal characteristics.
6-20
FRONT
1
3
a
1
b
2
2
3
1. Locknut
2. Adjusting bolt
3. Free play
4
EAU00703
Brake lever free play
adjustment
5
The front brake lever free play should
be adjusted to 2 ~ 5 mm at the brake
lever end.
6
7
8
9
5GM-9-E0 4/13/0 9:09 PM Page 62
PERIODIC MAINTENANCE AND MINOR REPAIR
FRONT
REAR
3
b 1
1
2
a
3
4
5
6
7
8
REAR
1
2
1. Locknut
2. Adjusting bolt
3. Free play
1. Wear indicator groove (×2)
w
1. Wear indicator groove (×2)
EAU01314
The rear brake lever free play should
be adjusted to 2 ~ 5 mm at the brake
lever end.
Loosen the locknut and turn the
adjusting bolt in direction a to
increase free play and in direction b
to decrease free play.
Be sure to tighten the locknut after
adjusting.
9
1
Checking the front and rear
brake pads
Each brake pad is provided with a
wear indicator groove, which allows
checking the brake pad for wear without disassembling the brake.
EW000101
When it is impossible to make the
proper adjustment, ask a Yamaha
dealer.
6-21
Inspect each wear indicator groove
and, as soon as one of them has
almost worn away, ask a Yamaha
dealer to replace the brake pads as a
set.
5GM-9-E0 4/13/0 9:09 PM Page 63
PERIODIC MAINTENANCE AND MINOR REPAIR
FRONT
REAR
1
1
1. Minimum level mark
1. Minimum level mark
EAU00731
Inspecting the brake fluid
level
Insufficient brake fluid may let air
enter the brake system, possibly
causing the brakes to become ineffective.
Before riding, check that the brake
fluid is above the minimum level and
replenish when necessary.
Observe these precautions:
8 When checking the fluid level,
make sure the top of the master
cylinder is level by turning the
handlebars.
8 Use only the designated quality
brake fluid. Otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.
Recommended brake fluid:
DOT 4
8 Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor brake performance.
6-22
8 Be careful that water does not
enter the master cylinder when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
8 Brake fluid may deteriorate painted surfaces or plastic parts.
Always clean up spilled fluid
immediately.
8 Have a Yamaha dealer check
the cause if the brake fluid level
goes down.
1
2
3
4
5
6
7
8
9
5GM-9-E0 4/13/0 9:09 PM Page 64
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00742
Brake fluid replacement
1
2
3
4
5
6
7
The brake fluid should be replaced
only by trained Yamaha service personnel. Have the Yamaha dealer
replace the following components
during periodic maintenance or when
they are damaged or leaking:
8 oil seals (every two years)
8 brake hoses (every four years)
EAU02962
Cable inspection and
lubrication
EW000112
w
Damage to the outer housing of
cables may lead to internal rusting
and interfere with the cable movement. Replace damaged cables as
soon as possible to prevent unsafe
conditions.
EAU03118*
Brake lever lubrication
Lubricate the cables and cable ends.
If a cable does not operate smoothly,
ask a Yamaha dealer to replace it.
Recommended lubricant:
Engine oil
8
9
6-23
Lubricate the pivoting parts of both
brake levers.
Recommended lubricant:
Engine oil
5GM-9-E0 4/13/0 9:09 PM Page 65
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU02939
Front fork inspection
Visual check
EW000115
1
Securely support the scooter so
there is no danger of it falling over.
2
w
3
EAU02965
Center and sidestand
lubrication
Check for scratches or damage on
the inner tube and excessive oil leakage from the front fork.
Lubricate the pivoting and mating
joints.
Check to see that the center and
sidestand move up and down
smoothly.
Recommended lubricant:
Engine oil
w
Operation check
1. Place the scooter on a level
place.
2. Hold the scooter in an upright
position and apply the front
brake.
3. Push down hard on the handlebars several times and check if
the fork rebounds smoothly.
cC
EW000114
6-24
5
6
7
8
EC000098
If any damage or unsmooth movement is found with the front fork,
consult a Yamaha dealer.
If the center and/or sidestand does
not move smoothly, consult a
Yamaha dealer.
4
9
5GM-9-E0 4/13/0 9:09 PM Page 66
PERIODIC MAINTENANCE AND MINOR REPAIR
EW000115
w
Securely support the scooter so
there is no danger of it falling over.
1
2
3
4
EAU00794
Steering inspection
5
6
7
8
9
EAU01144
Wheel bearings
Periodically inspect the condition of
the steering. Worn out or loose steering bearings may be dangerous.
Place a stand under the engine to
raise the front wheel off the ground.
Hold the lower end of the front forks
and try to move them forward and
backward. If any free play can be felt,
ask a Yamaha dealer to inspect and
adjust the steering. Inspection is easier if the front wheel is removed.
6-25
If there is play in the front or rear
wheel hub or if the wheel does not
turn smoothly, have a Yamaha dealer
inspect the wheel bearings.
5GM-9-E0 4/13/0 9:09 PM Page 67
PERIODIC MAINTENANCE AND MINOR REPAIR
1
1
1
2
2
2
1. Screw (×2)
2. Battery cover
1. Coolant reservoir tank cap
2. Fuse box (×2)
1
3
1. Battery
EAU01271
4
Battery
EAU00796
Battery cover removal
This scooter is equipped with a
sealed-type battery. Therefore it is
not necessary to check the electrolyte or fill the battery with distilled
water.
8 If the battery seems to have discharged, consult a Yamaha dealer.
8 If the scooter is equipped with
optional electrical accessories,
the battery tends to discharge
more quickly, so be sure to
recharge it periodically.
Pull up the right floorboard mat as
shown. Then remove the screws and
the battery cover.
NOTE:
The battery cover needs to be
removed to access the fuse box and
the coolant reservoir tank cap.
6-26
5
6
7
8
9
5GM-9-E0 4/13/0 9:09 PM Page 68
PERIODIC MAINTENANCE AND MINOR REPAIR
w
1
2
3
4
5
6
7
8
9
EW000116
Battery electrolyte is poisonous
and dangerous, causing severe
burns, etc. It contains sulfuric
acid. Avoid contact with skin, eyes
or clothing.
ANTIDOTE:
8 EXTERNAL: Flush with water.
8 INTERNAL: Drink large quantities of water or milk. Follow
with milk of magnesia, beaten
egg, or vegetable oil. Call a
physician immediately.
8 EYES: Flush with water for 15
minutes and get prompt medical attention.
Batteries
produce
explosive
gases. Keep sparks, flame, cigarettes etc., away. Ventilate when
charging or using in an enclosed
space. Always shield your eyes
when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
Battery storage
When the scooter is not used for a
month or longer, remove the battery,
fully charge it and store it in a cool,
dry place.
2
3
4
5
6
EC000102
cC
8 Completely recharge the battery before storing. Storing a
discharged battery can cause
permanent battery damage.
8 Use
a
battery
charger
designed for a sealed-type
(MF) battery. Using a conventional battery charger will
cause battery damage. If you
do not have a sealed-type battery charger, contact your
Yamaha dealer.
8 Always make sure the connections are correct when reinstalling the battery.
6-27
8
7
7
1.
2.
3.
4.
5.
6.
7.
8.
1
Main fuse
Clock fuse (back up)
Radiator fan fuse
Ignition fuse
Headlight fuse
Signaling system fuse
Spare fuse (×4)
Spare main fuse
EAU03095*
Fuse replacement
The main fuse and fuse box are
located beside the battery.
1. Remove the battery cover by
removing the screws.
5GM-9-E0 4/13/0 9:09 PM Page 69
PERIODIC MAINTENANCE AND MINOR REPAIR
2. If a fuse is blown, turn off the
ignition switch and the switch of
the circuit in question. Install a
new fuse of specified amperage.
Turn on the switches, and see if
the electrical device operates. If
the fuse immediately blows
again, consult a Yamaha dealer.
cC
EC000103
Do not use fuses of higher amperage rating than those recommended. Substitution of a fuse of
improper rating can cause extensive electrical system damage and
possibly a fire.
1
EAU03112*
Headlight bulb replacement
This scooter is equipped with quartz
bulb headlights.
If a headlight bulb burns out, replace
the bulb as follows:
1. Place the scooter on the centerstand.
2. Remove panel B. (See page 6-8
for panel removal and installation
procedures.)
2
1
2
3
1. Coupler (×2)
2. Bulb holder cover (×2)
3. Disconnect the headlight coupler
and remove the bulb holder
cover.
4
5
6
7
Specified fuses:
Main fuse: 30 A
Clock fuse (back up): 10 A
Radiator fan fuse: 4 A
Ignition fuse: 7.5 A
Headlight fuse: 15 A
Signaling system fuse: 15 A
8
9
6-28
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PERIODIC MAINTENANCE AND MINOR REPAIR
1
1
2
1
3
4
5
1. Bulb holder (×2)
4. Unhook the bulb holder
remove the defective bulb.
w
6
7
1. Don’t touch
to
EW000119
5. Put a new bulb into position and
secure it in place with the bulb
holder.
Keep flammable products and your
hands away from a bulb while it is
on, as it is hot. Do not touch a bulb
until it cools down.
8
cC
EC000105
Avoid touching the glass part of a
bulb. Keep it free from oil; otherwise, the transparency of the
glass, life of the bulb, and luminous flux will be adversely affected. If oil gets on a bulb, thoroughly
clean it with a cloth moistened
with alcohol or lacquer thinner.
9
6. Install the bulb holder cover and
connect the headlight coupler.
7. Install the panel.
If necessary, ask a Yamaha dealer to
adjust the headlight beam.
6-29
5GM-9-E0 4/13/0 9:09 PM Page 71
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03115*
EAU03111*
Tail/brake light bulb
replacement
Front turn signal light bulb
replacement
1. Place the scooter on the centerstand.
2. Remove panel A. (See page 6-6
for panel removal and installation
procedures.)
1
1. Bulb socket (×2)
1. Place the scooter on the centerstand.
2. Remove panel B. (See page 6-8
for panel removal and installation
procedures.)
1
2
3
4
3. Turn the tail/brake light bulb
socket
counterclockwise
to
remove it.
4. Remove the defective bulb by
pushing it inward and turning it
counterclockwise.
5. Install a new bulb by pushing it
inward and turning it clockwise.
6. Install the tail/brake light bulb
socket into the original position
and turn it clockwise.
7. Install the panel.
6-30
5
6
7
8
9
5GM-9-E0 4/13/0 9:09 PM Page 72
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03116*
Rear turn signal light bulb
replacement
1
1
2
3
4
5
6
7
8
9
1. Place the scooter on the centerstand.
2. Remove panel A. (See page 6-6
for panel removal and installation
procedures.)
1. Bulb socket
1
1. Bulb socket
3. Remove the front turn signal light
bulb socket by turning it counterclockwise.
4. Remove the defective bulb by
pushing it inward and turning it
counterclockwise.
5. Install a new bulb by pushing it
inward and turning it clockwise.
6. Install the front turn signal light
bulb socket into the original position and turn it clockwise.
7. Install the panel.
3. Turn the rear turn signal light bulb
socket
counterclockwise
to
remove it.
4. Pull out the defective bulb.
5. Install a new bulb by pushing it
inward.
6. Install the rear turn signal light
bulb socket into the original position and turn it clockwise.
7. Install the panel.
6-31
5GM-9-E0 4/13/0 9:09 PM Page 73
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03117*
License light bulb
replacement
1
1. Place the scooter on the centerstand.
2. Remove panel A. (See page 6-6
for panel removal and installation
procedures.)
2
1
1
1. Screw (×2)
1. Bulb
3. Remove the screws holding the
license light lens.
4. Remove the license light lens
and pull out the defective bulb.
5. Install a new bulb.
6. Install the license light lens and
screws.
7. Install the panel.
3
4
5
6
7
8
9
6-32
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01008
Troubleshooting
1
2
3
4
5
6
7
8
9
Although Yamaha scooter receive a
rigid inspection before shipment from
the factory, trouble may occur during
operation.
Any problem in the fuel, compression, or ignition systems can cause
poor starting and loss of power. The
troubleshooting chart describes a
quick, easy procedure for making
checks.
If your scooter requires any repair,
bring it to a Yamaha dealer. The
skilled technicians at a Yamaha dealership have the tools, experience,
and know-how to properly service
your scooter. Use only genuine
Yamaha parts on your scooter.
Imitation parts may look like Yamaha
parts, but they are often inferior.
Consequently, they have a shorter
service life and can lead to expensive
repair bills.
6-33
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01581*
Troubleshooting charts
EW000125
w
1
Never check the fuel system while smoking or in the vicinity of an open flame.
2
1. Fuel
Enough fuel.
Go to compression check.
No fuel.
Supply fuel.
3
Check if there is fuel
in the fuel tank.
2. Compression
4
Engine doesn’t start, go to
compression check.
5
There is compression.
Go to ignition check.
No compression.
Ask a Yamaha dealer to inspect.
Use electric starter.
6
3. Ignition
Remove spark
plug and check
electrodes.
Wet.
Wipe clean with dry cloth and correct
spark gap or replace spark plug.
Open throttle half-way and start
the engine.
Dry.
Ask a Yamaha dealer to inspect.
Engine doesn’t start, go to battery
check.
7
8
4. Battery
Engine turns over
quickly.
Battery good.
Engine turns over
slowly.
Check connections or
recharge.
Engine doesn’t start, ask a
Yamaha dealer to inspect.
Use electric starter.
6-34
9
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PERIODIC MAINTENANCE AND MINOR REPAIR
Engine overheating
EW000070
w
1
2
3
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Open the radiator cap as follows. Wait until the
engine has cooled. Remove the radiator cap stopper by removing the screw. Place a thick rag like a towel over
the radiator cap and slowly rotate the cap counterclockwise to the detent. This procedure allows any residual
pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it.
4
5
Level is low, check the
cooling system for leakage.
6
7
Wait until the engine
has cooled.
Check the coolant level in the
reservoir tank and/or radiator.
Level is OK.
8
9
Leakage.
Ask a Yamaha dealer to inspect
and repair the cooling system.
No
leakage.
Add coolant (See NOTE.)
Restart the engine. If the engine overheats again, ask a
Yamaha dealer to inspect and repair the cooling system.
NOTE:
If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recommended coolant as soon as possible.
6-35
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SCOOTER CARE AND STORAGE
Care....................................................................................................7-1
Storage ...............................................................................................7-4
7
5GM-9-E0 4/13/0 9:10 PM Page 78
EAU01522
SCOOTER CARE AND STORAGE
Care
1
2
3
4
5
6
7
The exposure of its technology
makes a scooter charming but also
vulnerable. Although high-quality
components are used, they are not
all rust-resistant. While a rusty
exhaust pipe may remain unnoticed
on a car, it does look unattractive on
a scooter. Frequent and proper care,
however, will keep your scooter looking good, extend its life and maintain
its performance. Moreover, the warranty states that the vehicle must be
properly taken care of. For all these
reasons, it is recommended that you
observe the following cleaning and
storing precautions.
Before cleaning
1. Cover up the muffler outlet with a
plastic bag.
2. Make sure that all caps and 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
tooth or bottle brush, but never
apply such products onto seals,
gaskets and wheel axles. Always
rinse the dirt and degreaser off
with water.
8
9
7-1
Cleaning
After normal use
Remove dirt with warm water, a neutral detergent and a soft clean
sponge, then rinse with plenty of
clean water. Use a brush for hard-toreach parts. Tougher dirt and insects
will come off more easily if the area is
covered with a wet cloth for a few
minutes before cleaning.
cC
ECA00011
8 Avoid using strong acidic
wheel cleaners. If you do use
such products for hard-toremove dirt, do not leave it on
any longer than instructed,
then thoroughly rinse it off
with water, immediately dry
the area and apply a corrosion
protection spray.
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SCOOTER CARE AND STORAGE
8 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.
8 Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline),
rust removers or inhibitors,
brake fluid, antifreeze or electrolyte.
8 Do not use high-pressure
washers or steam-jet cleaners
since they cause water seepage and deterioration in the
following areas: seals (of
wheel bearings, swingarm
bearings, bearings, forks and
brakes), electric components
(couplers, connectors, instruments, switches and lights),
breather hoses and vents.
8 For scooters equipped with a
windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the windshield. Test the product on a
small hidden part of the windshield to make sure they do
not leave any marks. If the
windshield is scratched, use a
quality plastic polishing compound after washing.
7-2
After riding in the rain, near the sea
or on salt-sprayed roads
Since sea salt or salt sprayed on the
roads in the winter are extremely corrosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads. (Salt sprayed
in the winter may remain on the roads
well into spring.)
1. Clean your scooter with cold
water and soap after the engine
has cooled down.
cC
1
2
3
4
5
ECA00012
Do not use warm water since it
increases the corrosive action of
the salt.
6
7
8
2. Be sure to apply a corrosion protection spray on all (even
chrome- and nickel-plated) metal
surfaces to prevent corrosion.
9
5GM-9-E0 4/13/0 9:10 PM Page 80
SCOOTER CARE AND STORAGE
1
2
3
4
5
6
7
8
After cleaning
1. Dry the scooter with a chamois
or an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stainlesssteel parts, including the exhaust
system. (Even the thermally
induced discoloring of stainlesssteel exhaust systems can be
removed through polishing.)
3. To prevent corrosion, it is recommended to apply a corrosion protection spray on all (even
chrome- and nickel-plated) metal
surfaces.
4. Use spray oil as a universal
cleaner to remove any remaining
dirt.
5. Touch up minor paint damage
caused by stones, etc.
6. Wax all painted surfaces.
7. Let the scooter dry completely
before storing it or covering it.
EWA00002
w
Make sure that there is no oil or
wax on the brakes and tires. If necessary, clean the brake discs and
linings with a regular brake disc
cleaner or acetone, and wash the
tires with warm water and mild
soap. Then, carefully test the
scooter for its braking performance and cornering behavior.
9
7-3
cC
ECA00013
8 Apply spray oil and wax sparingly and wipe off any excess.
8 Never apply oil or wax on rubber and plastic parts, but treat
them with a suitable care product.
8 Avoid using abrasive polishing compounds as they wear
away the paint.
NOTE:
Consult a Yamaha dealer for advice
on what products to use.
5GM-9-E0 4/13/0 9:10 PM Page 81
SCOOTER CARE AND STORAGE
Storage
Short-term
Always store your scooter in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
cC
ECA00015
8 Storing the scooter in a poorly
ventilated room or covering it
with a tarp while it is still wet
will allow water and humidity
to seep in and cause rust.
8 To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemicals are stored.
Long-term
Before storing your scooter for several months:
1. Follow all the instructions in 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. Only for scooters equipped with
a fuel cock which has an “OFF”
position: Turn the fuel cock to
“OFF”.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to
protect the cylinder, piston rings,
etc. from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine
oil into the spark plug bore.
c. Install the spark plug cap onto
the spark plug and place the
spark plug on the cylinder
head so that the electrodes
are grounded. (This will limit
sparking during the next
step.)
d. Turn the engine over several
times with the starter. (This
will coat the cylinder wall with
oil.)
e. Remove the spark plug cap
from the spark plug, install
the spark plug and then the
spark plug cap.
w
EWA00003
When turning the engine over, be
sure to ground the spark plug electrodes to prevent damage or injury
from sparking.
7-4
7
5GM-9-E0 4/13/0 9:10 PM Page 82
SCOOTER CARE AND STORAGE
1
2
3
4
5
6
6. Lubricate all control cables and
the pivoting points of all levers
and pedals as well as of the
sidestand/centerstand.
7. Check and, if necessary, correct
the tire air pressure, then raise
the scooter so that both of its
wheels are off the ground.
Alternatively, turn the wheels a
little every month in order to prevent the tires from becoming
degraded in one spot.
8. Cover up the muffler outlet with a
plastic bag to prevent moisture
from entering.
9. Remove the battery and fully
charge it. Store it in a cool, dry
place and recharge 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 information, see
“Battery storage” in the chapter
“PERIODIC
MAINTENANCE
AND MINOR REPAIRS”.
NOTE:
Make any necessary repairs before
storing the scooter.
7
8
9
7-5
5GM-9-E0 4/13/0 9:10 PM Page 83
SPECIFICATIONS
Specifications .....................................................................................8-1
How to use the conversion table ........................................................8-5
8
5GM-9-E0 4/13/0 9:10 PM Page 84
EAU01038
SPECIFICATIONS
Specifications
1
Model
Engine oil
YP250
Type
Dimensions
2
Overall length
Overall width
3
4
5
6
Overall height
2,140 mm
Wheelbase
1,535 mm
Minimum turning radius
40° 50°C
SAE 10W/40
SAE 15W/40
SAE 20W/40
SAE 20W/50
120 mm
2,700 mm
Recommended engine oil
classification
168 kg
Engine
API Service SE, SF, SG type
or higher
cC
Engine type
Liquid-cooled 4-stroke, SOHC
7
Cylinder arrangement
Forward inclined single
cylinder
8
Displacement
249 cm3
Bore × Stroke
69.0 × 66.8 mm
9
10° 20° 30°
1,350 mm
730 mm
Basic weight (with oil and full
fuel tank)
0°
SAE 10W/30
780 mm
Seat height
Ground clearance
–20° –10°
Compression ratio
10:1
Starting system
Electric starter
Lubrication system
Wet sump
Be sure to use motor oils that do not contain anti-friction
modifiers. Passenger car motor oils (often labeled “Energy
Conserving”) contain anti-friction additives which will cause
clutch and/or starter clutch slippage, resulting in reduced
component life and poor engine performance.
Capacity
8-1
Periodic oil change
1.2 L
Total amount
1.4 L
5GM-9-E0 4/13/0 9:10 PM Page 85
SPECIFICATIONS
Final gear oil
Chassis
1
Type
SAE 10W30 type SE motor oil
Frame type
Final gear case capacity
0.25 L
Caster angle
28°
Wet element
Trail
103 mm
Air filter
Fuel
Tire
Type
Regular unleaded gasoline
Fuel tank capacity
12 L
Type × quantity
Y28V-1E × 1
Manufacturer
TEIKEI
3
Type
Tubeless
Size
110/90-12 64L
Manufacturer/
model
INOUE / MB67
MICHELIN / BOPPER
5
Type
Tubeless
6
Size
130/70-12 62L
Manufacturer/
model
INOUE / MB67
MICHELIN / BOPPER
7
187 kg
8
4
Rear
Spark plug
Manufacturer/type
NGK / DR8EA
Spark plug gap
0.6 ~ 0.7 mm
Dry, centrifugal automatic
Transmission
Primary reduction system
2
Front
Carburetor
Clutch type
Steel tube underbone
Maximum load*
Helical gear
Air pressure (cold tire)
up to 90 kg load*
Primary reduction ratio
40/15 (2.666)
Secondary reduction system
Helical gear
Front
175 kPa (1.75 kg/cm2, 1.75 bar)
Secondary reduction ratio
38/15 (2.533)
Rear
200 kPa (2.00 kg/cm2, 2.00 bar)
Transmission type
V-belt automatic
Operation
Centrifugal automatic type
8-2
9
5GM-9-E0 4/13/0 9:10 PM Page 86
SPECIFICATIONS
1
90 kg load ~ maximum
2
3
4
5
Suspension
load*
Front
200 kPa (2.00 kg/cm2, 2.00 bar)
Rear
225 kPa (2.25 kg/cm2, 2.25 bar)
Telescopic fork
Rear
Unit swing
Shock absorbers
* Load is total weight of cargo, rider, passenger and accessories.
Wheels
Front
Front
Coil spring/oil damper
Rear
Coil spring/oil damper
Wheel travel
Type
Cast wheel
Size
12 × MT2.75
Rear
6
Front
Front
100 mm
Rear
90 mm
Electrical
Type
Cast wheel
Ignition system
Size
12 × MT3.50
Charging system
Brakes
7
Front
8
9
Type
Single disc brake
Operation
Right hand operation
Fluid
DOT 4
Type
A.C. magneto
Standard output
14 V, 19.5 A @ 5,000 r/min
Type
GT7B-4
Voltage, capacity
12 V, 6.5 AH
Battery
Rear
Headlight bulb type
Type
Single disc brake
Operation
Left hand operation
Fluid
DOT 4
T.C.I. (digital)
Halogen bulb
Bulb voltage, wattage × quantity
8-3
Headlight
12 V, 60/55 W × 1
12 V, 55 W × 1
Tail/brake light
12 V, 5/21 W × 2
5GM-9-E0 4/13/0 9:10 PM Page 87
SPECIFICATIONS
Front turn signal light
12 V, 21 W × 2
Rear turn signal light
12 V, 16 W × 2
Auxiliary light
12 V, 5 W × 1
License plate light
12 V, 5 W × 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
1
2
3
4
Fuses
Main fuse
30 A
Headlight fuse
15 A
Signaling system fuse
15 A
Ignition fuse
7.5 A
Radiator fan fuse
4A
Clock fuse (back up)
10 A
5
6
7
8
9
8-4
5GM-9-E0 4/13/0 9:10 PM Page 88
SPECIFICATIONS
EAU01064
HOW TO USE THE CONVERSION TABLE
2
All specification data in this manual are listed in SI and
METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.
3
Ex.
1
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit
Multiplier
Imperial unit
Torque
m • kg
m • kg
cm • kg
cm • kg
7.233
86.794
0.0723
0.8679
ft• lb
in• lb
ft • lb
in • lb
Weight
kg
g
2.205
0.03527
lb
oz
Speed
km/hr
0.6214
mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
6
Volume/
Capacity
cc (cm3)
cc (cm3)
lt (liter)
lt (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cu • in
qt (IMP liq.)
gal (IMP liq.)
7
Misc.
kg/mm
kg/cm2
Centigrade(°C)
55.997
14.2234
9/5 + 32
lb/in
psi (lb/in2)
Fahrenheit(°F)
4
5
METRIC
** mm
2 mm
MULTIPLIER
×
×
0.03937
0.03937
IMPERIAL
=
=
** in
0.08 in
8
9
8-5
5GM-9-E0 4/13/0 9:10 PM Page 89
CONSUMER INFORMATION
Identification number records .............................................................9-1
Key identification number ...................................................................9-1
Vehicle identification number..............................................................9-1
Model label .........................................................................................9-2
9
5GM-9-E0 4/13/0 9:10 PM Page 90
EAU01039
CONSUMER INFORMATION
EAU02944
Identification number
records
1
2
3
4
5
Record the key identification number,
vehicle identification number and
model label information in the spaces
provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle
is stolen.
1
1. Key identification number
1. Vehicle identification number
EAU01041
1. KEY IDENTIFICATION
NUMBER:
6
7
1
2. VEHICLE IDENTIFICATION
NUMBER:
Key identification number
The key identification number is
stamped on the key tag.
Record this number in the space provided and use it for reference when
obtaining a new key.
8
9
3. MODEL LABEL INFORMATION:
1
6
9-1
EAU01044
Vehicle identification
number
The vehicle identification number is
stamped into the frame.
NOTE:
The vehicle identification number is
used to identify your scooter and may
be used to register your scooter with
the licensing authority in your state.
5GM-9-E0 4/13/0 9:10 PM Page 91
CONSUMER INFORMATION
1
1
2
1. Model label
4
EAU01804
Model label
5
The model label is affixed to the
frame under the rider seat. (See page
3-12 for rider seat removal and installation procedures.)
Record the information on this label
in the space provided. This information will be needed to order spare
parts from your Yamaha dealer.
6
7
8
9
9-2
5GM-9-E0 4/13/0 9:10 PM Page 92
INDEX
A
Acceleration.............................................5-2
Air filter and V-belt case filter
cleaning ..............................................6-16
Air flow louver........................................6-18
Antitheft alarm (optional) .........................3-5
B
Battery ...................................................6-26
Battery cover removal ...........................6-26
Brake fluid replacement.........................6-23
Brake lever free play adjustment...........6-20
Brake lever lubrication...........................6-23
Braking ....................................................5-2
C
Cable inspection and lubrication ...........6-23
Care.........................................................7-1
Carrier (option) ......................................3-16
Catalyzer ...............................................3-12
Center and sidestand lubrication...........6-24
Checking the front and rear brake
pads ....................................................6-21
Coolant ..................................................6-15
Coolant temperature gauge.....................3-5
D
Description ..............................................2-1
Diagnosis device .....................................3-4
Digital clock .............................................3-6
Dimmer switch.........................................3-6
E
Engine break-in .......................................5-3
Engine oil...............................................6-11
Engine stop switch ..................................3-9
F
Final gear oil replacement .....................6-14
Front brake lever .....................................3-9
Front fork inspection..............................6-24
Front turn signal light bulb
replacement ........................................6-30
Fuel .......................................................3-11
Fuel gauge ..............................................3-5
Fuel tank cap.........................................3-10
Fuse replacement..................................6-27
H
Handlebar switches .................................3-6
Dimmer switch ......................................3-6
Engine stop switch ................................3-9
Pass switch ...........................................3-6
Turn signal switch .................................3-7
Horn switch ...........................................3-7
Light switch ...........................................3-7
Start switch ...........................................3-9
Headlight beam variation.........................3-8
Headlight bulb replacement...................6-28
High beam indicator light.........................3-2
Horn switch..............................................3-7
How to use the conversion table .............8-5
I
Identification number records ..................9-1
Indicator lights .........................................3-2
Turn indicator lights ..............................3-2
High beam indicator light ......................3-2
Oil change indicator light ......................3-2
Inspecting the brake fluid level ..............6-22
K
Key identification number ........................9-1
L
License light bulb replacement..............6-32
Light switch..............................................3-7
M
Main switch / Steering lock......................3-1
Model label ..............................................9-2
O
Oil change indicator light circuit
check ....................................................3-3
Oil change indicator light .........................3-2
P
Panel A....................................................6-6
Panel B....................................................6-8
Panel C....................................................6-8
Panel removal and installation ................6-6
Parking ....................................................5-4
Pass switch .............................................3-6
Periodic maintenance and
lubrication .............................................6-3
Pre-operation check list...........................4-1
5GM-9-E0 4/13/0 9:10 PM Page 93
INDEX
R
Rear brake lever....................................3-10
Rear shock absorber adjustment ..........3-15
Rear turn signal light bulb
replacement ........................................6-31
Rider seat ..............................................3-12
Rider seat adjustment ...........................3-13
S
Sidestand ..............................................3-16
Sidestand switch operation check .........3-17
Spark plug .............................................6-10
Specifications ..........................................8-1
Speedometer...........................................3-4
Start switch..............................................3-9
Starting a cold engine..............................5-1
Starting off ...............................................5-2
Steering inspection................................6-25
Storage....................................................7-4
Storage compartments ..........................3-14
T
Tail/brake light bulb replacement ..........6-30
Tires ......................................................6-18
Tool kit.....................................................6-1
Troubleshooting.....................................6-33
Troubleshooting chart............................6-34
Turn indicator lights .................................3-2
Turn signal switch....................................3-7
V
Vehicle identification number ..................9-1
W
Wheel bearings .....................................6-25
Wheels ..................................................6-20
5GM-9-E0 4/13/0 9:10 PM Page 94
5GM-9-E0 4/13/0 9:10 PM Page 95
5GM-9-E0(Hyoushi) 4/13/0 9:16 PM Page 1 (1,1)
(Magenta plate)
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
99·10–1.6×1(E) !