periodic maintenance and adjustment

periodic maintenance and adjustment
Read this manual carefully before operating this vehicle.
OWNER’S MANUAL
XC125E
4P7-F8199-E2
DIC183
U4P7E2E0.book Page 1 Thursday, August 20, 2009 9:44 AM
EAU46090
Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
U4P7E2E0.book Page 1 Thursday, August 20, 2009 9:44 AM
INTRODUCTION
EAU10113
Welcome to the Yamaha world of motorcycling!
As the owner of the XC125E, you are benefiting from Yamaha’s vast experience and newest technology regarding the design
and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XC125E. The Owner’s Manual
does not only instruct you in how to operate, inspect and maintain your scooter, but also in how to safeguard yourself and
others from trouble and injury.
In addition, the many tips given in this manual will help keep your scooter in the best possible condition. If you have any further questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!
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 a Yamaha dealer.
EWA12411
WARNING
Please read this manual carefully and completely before operating this scooter.
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IMPORTANT MANUAL INFORMATION
EAU10132
Particularly important information is distinguished in this manual by the following notations:
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury
or death.
WARNING
NOTICE
TIP
A WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to the
vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
U4P7E2E0.book Page 2 Thursday, August 20, 2009 9:44 AM
IMPORTANT MANUAL INFORMATION
EAU37230
XC125E
OWNER’S MANUAL
©2009 by Yamaha Motor Co., Ltd.
1st edition, July 2009
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in China.
U4P7E2E0.book Page 1 Thursday, August 20, 2009 9:44 AM
TABLE OF CONTENTS
SAFETY INFORMATION ..................1-1
Further safe-riding points ................1-5
FOR YOUR SAFETY –
PRE-OPERATION CHECKS ............. 4-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
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
INSTRUMENT AND CONTROL
FUNCTIONS .......................................3-1
Main switch/steering lock ................3-1
Keyhole cover .................................3-2
Indicator, indicator lights and
warning light ................................3-2
Speedometer unit ...........................3-3
Self-diagnosis device ......................3-4
Fuel gauge ......................................3-4
Anti-theft alarm (optional) ...............3-4
Handlebar switches ........................3-5
Front brake lever ............................3-5
Rear brake lever .............................3-6
Fuel tank cap ..................................3-6
Fuel .................................................3-7
Catalytic converters ........................3-8
Seat ................................................3-8
Helmet holders ...............................3-9
Storage compartments .................3-10
Carrier ...........................................3-11
Luggage hook ...............................3-11
Sidestand ......................................3-11
Ignition circuit cut-off system ........3-12
PERIODIC MAINTENANCE AND
ADJUSTMENT ................................... 6-1
Periodic maintenance chart for
the emission control system ....... 6-2
General maintenance and
lubrication chart .......................... 6-3
Removing and installing cowlings
and panels .................................. 6-6
Checking the spark plug ................. 6-8
Engine oil ....................................... 6-9
Final transmission oil .................... 6-11
Air filter and V-belt case air filter
elements ................................... 6-12
Checking the throttle cable free
play ........................................... 6-14
Valve clearance ............................ 6-15
Tires ............................................. 6-15
Cast wheels ................................. 6-17
Checking the front brake lever
free play .................................... 6-17
Adjusting the rear brake lever
free play .................................... 6-17
Checking the front brake pads
and rear brake shoes ............... 6-18
Checking the front brake fluid
level .......................................... 6-19
Changing the brake fluid .............. 6-20
Checking and lubricating
the cables ................................. 6-20
Checking and lubricating
the throttle grip and cable ......... 6-20
Lubricating the front and rear
brake levers .............................. 6-21
Checking and lubricating the
centerstand and sidestand ....... 6-21
Checking the front fork ................. 6-22
Checking the steering .................. 6-23
Checking the wheel bearings ....... 6-23
Battery ......................................... 6-23
Replacing the fuse ....................... 6-25
Replacing the headlight bulb ....... 6-25
Replacing a front turn signal light
bulb ........................................... 6-26
Rear turn signal light and tail/brake
light ........................................... 6-27
Replacing the auxiliary light
bulb ........................................... 6-27
Troubleshooting ........................... 6-28
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TABLE OF CONTENTS
Troubleshooting chart ...................6-29
SCOOTER CARE AND STORAGE ...7-1
Matte color caution .........................7-1
Care ................................................7-1
Storage ...........................................7-3
SPECIFICATIONS .............................8-1
CONSUMER INFORMATION.............9-1
Identification numbers ....................9-1
U4P7E2E0.book Page 1 Thursday, August 20, 2009 9:44 AM
SAFETY INFORMATION
EAU10264
1
Be a Responsible Owner
As the vehicle’s owner, you are responsible for the safe and proper operation
of your scooter.
Scooters are single-track vehicles.
Their safe use and operation are dependent upon the use of proper riding
techniques as well as the expertise of
the operator. Every operator should
know the following requirements before
riding this scooter.
He or she should:
● Obtain thorough instructions from
a competent source on all aspects
of scooter operation.
● Observe the warnings and maintenance requirements in this Owner’s Manual.
● Obtain qualified training in safe
and proper riding techniques.
● Obtain professional technical service as indicated in this Owner’s
Manual and/or when made necessary by mechanical conditions.
Safe Riding
Perform the pre-operation checks each
time you use the vehicle to make sure it
is in safe operating condition. Failure to
inspect or maintain the vehicle properly
increases the possibility of an accident
or equipment damage. See page 4-1
for a list of pre-operation checks.
● This scooter is designed to carry
the operator and a passenger.
● The failure of motorists to detect
and recognize scooters in traffic is
the predominating cause of automobile/scooter accidents. Many
accidents have been caused by an
automobile driver who did not see
the scooter. Making yourself conspicuous appears to be very effective in reducing the chance of this
type of accident.
Therefore:
• Wear a brightly colored jacket.
• Use extra caution when you are
approaching
and
passing
through intersections, since intersections are the most likely
places for scooter accidents to
occur.
1-1
●
●
• Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.
Many accidents involve inexperienced operators. In fact, many operators who have been involved in
accidents do not even have a current driver’s license.
• Make sure that you are qualified
and that you only lend your
scooter to other qualified operators.
• Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
• We recommend that you practice riding your scooter where
there is no traffic until you have
become thoroughly familiar with
the scooter and all of its controls.
Many accidents have been caused
by error of the scooter operator. A
typical error made by the operator
is veering wide on a turn due to ex-
U4P7E2E0.book Page 2 Thursday, August 20, 2009 9:44 AM
SAFETY INFORMATION
●
●
cessive speed or undercornering
(insufficient lean angle for the
speed).
• Always obey the speed limit and
never travel faster than warranted by road and traffic conditions.
• Always signal before turning or
changing lanes. Make sure that
other motorists can see you.
The posture of the operator and
passenger is important for proper
control.
• The operator should keep both
hands on the handlebar and
both feet on the operator footrests during operation to maintain control of the scooter.
• The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.
Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.
Never ride under the influence of
alcohol or other drugs.
●
This scooter is designed for onroad use only. It is not suitable for
off-road use.
Protective apparel
The majority of fatalities from scooter
accidents are the result of head injuries. The use of a safety helmet is the
single most critical factor in the prevention or reduction of head injuries.
● Always wear an approved helmet.
● Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
● The use of a jacket, substantial
shoes, trousers, gloves, etc., is effective in preventing or reducing
abrasions or lacerations.
● Never wear loose-fitting clothes,
otherwise they could catch on the
control levers or wheels and cause
injury or an accident.
● Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust system become very hot during or after operation and can cause burns.
1-2
●
A passenger should also observe
the above precautions.
Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing carbon monoxide can cause headaches,
dizziness, drowsiness, nausea, confusion, and eventually death.
Carbon Monoxide is a colorless, odorless, tasteless gas which may be
present even if you do not see or smell
any engine exhaust. Deadly levels of
carbon monoxide can collect rapidly
and you can quickly be overcome and
unable to save yourself. Also, deadly
levels of carbon monoxide can linger
for hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poisoning, leave the area immediately, get
fresh air, and SEEK MEDICAL TREATMENT.
● Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rapidly reach dangerous levels.
1
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SAFETY INFORMATION
●
1
●
Do not run engine in poorly ventilated or partially enclosed areas
such as barns, garages, or carports.
Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Loading
Adding accessories or cargo to your
scooter can adversely affect stability
and handling if the weight distribution of
the scooter is changed. To avoid the
possibility of an accident, use extreme
caution when adding cargo or accessories to your scooter. Use extra care
when riding a scooter that has added
cargo or accessories. Here, along with
the information about accessories below, are some general guidelines to follow if loading cargo to your scooter:
The total weight of the operator, passenger, accessories and cargo must
not exceed the maximum load limit.
Operation of an overloaded vehicle
could cause an accident.
Maximum load:
167 kg (368 lb)
When loading within this weight limit,
keep the following in mind:
● Cargo and accessory weight
should be kept as low and close to
the scooter as possible. Securely
pack your heaviest items as close
to the center of the vehicle as possible and make sure to distribute
the weight as evenly as possible
on both sides of the scooter to minimize imbalance or instability.
● Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely
attached to the scooter before
riding. Check accessory mounts
and cargo restraints frequently.
• Properly adjust the suspension
for your load (suspension-adjustable models only), and
check the condition and pressure of your tires.
1-3
●
• Never attach any large or heavy
items to the handlebar, front
fork, or front fender. Such items
can create unstable handling or
a slow steering response.
This vehicle is not designed to
pull a trailer or to be attached to
a sidecar.
Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are available only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection to
Yamaha manufacture parts and accessories or offer other modifications for
Yamaha vehicles. Yamaha is not in a
position to test the products that these
aftermarket
companies
produce.
Therefore, Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or
modifications not specifically recommended by Yamaha, even if sold and
installed by a Yamaha dealer.
U4P7E2E0.book Page 4 Thursday, August 20, 2009 9:44 AM
SAFETY INFORMATION
Aftermarket Parts, Accessories, and
Modifications
While you may find aftermarket products similar in design and quality to
genuine Yamaha accessories, recognize that some aftermarket accessories
or modifications are not suitable because of potential safety hazards to you
or others. Installing aftermarket products or having other modifications performed to your vehicle that change any
of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or death.
You are responsible for injuries related
to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Loading” when mounting accessories.
● Never install accessories or carry
cargo that would impair the performance of your scooter. Carefully
inspect the accessory before using
it to make sure that it does not in
any way reduce ground clearance
or cornering clearance, limit sus-
pension travel, steering travel or
control operation, or obscure lights
or reflectors.
• Accessories fitted to the handlebar or the front fork area can
create instability due to improper
weight distribution or aerodynamic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
• Bulky or large accessories may
seriously affect the stability of
the scooter due to aerodynamic
effects. Wind may attempt to lift
the scooter, or the scooter may
become unstable in cross
winds. These accessories may
also cause instability when
passing or being passed by
large vehicles.
• Certain accessories can displace the operator from his or
her normal riding position. This
improper position limits the freedom of movement of the opera-
1-4
●
tor and may limit control ability,
therefore, such accessories are
not recommended.
Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the
scooter’s electrical system, an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Aftermarket Tires and Rims
The tires and rims that came with your
scooter were designed to match the
performance capabilities and to provide
the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be
appropriate. Refer to page 6-15 for tire
specifications and more information on
replacing your tires.
1
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SAFETY INFORMATION
EAU45371
Further safe-riding points
●
1
●
Make sure to signal clearly when
making turns.
Left turn
●
●
●
Right turn
●
●
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.
Slow down as you approach a corner or turn. Once you have completed a turn, accelerate slowly.
Be careful when passing parked
cars. A driver might not see you
and open a door in your path.
Railroad crossings, streetcar rails,
iron plates on road construction
sites, and manhole covers become extremely slippery when
wet. Slow down and cross them
with caution. Keep the scooter upright, otherwise it could slide out
from under you.
The brake pads and linings could
get wet when you wash the scooter. After washing the scooter,
check the brakes before riding.
Always wear a helmet, gloves,
trousers (tapered around the cuff
and ankle so they do not flap), and
a bright colored jacket.
1-5
●
Do not carry too much luggage on
the scooter. An overloaded scooter is unstable. Use a strong cord to
secure any luggage to the carriers.
A loose load will affect the stability
of the scooter and could divert
your attention from the road. (See
page 1-3.)
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DESCRIPTION
EAU10410
Left view
1
2
3
4
5
2
9
1.
2.
3.
4.
5.
6.
7.
8.
8
7
6
9. Sidestand (page 3-11)
Battery (page 6-23)
Fuse (page 6-25)
V-belt case air filter element (page 6-12)
Air filter element (page 6-12)
Final transmission oil filler cap (page 6-11)
Final transmission oil drain bolt (page 6-11)
Engine oil drain bolt (page 6-9)
Centerstand (page 6-21)
2-1
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DESCRIPTION
EAU10420
Right view
1
2
3
4
5 6
7
2
9
1.
2.
3.
4.
5.
6.
7.
8.
8
9. Engine oil filler cap (page 6-9)
Carrier (page 3-11)
Grab bar (page 5-2)
Fuel tank cap (page 3-6)
Rear storage compartment (page 3-10)
Helmet holder (page 3-9)
Front storage compartment (page 3-10)
Luggage hook (page 3-11)
Spark plug (page 6-8)
2-2
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DESCRIPTION
EAU10430
Controls and instruments
1
2
3
4
5
6
7
2
9
1.
2.
3.
4.
5.
6.
7.
8.
8
9. Oil change indicator reset switch (page 3-2)
Rear brake lever (page 3-6)
Left handlebar switches (page 3-5)
Speedometer unit (page 3-3)
Fuel gauge (page 3-4)
Right handlebar switch (page 3-5)
Throttle grip (page 6-14)
Front brake lever (page 3-5)
Main switch/steering lock and keyhole cover (pages 3-1 and 3-2)
2-3
chapter3 Page 1 Thursday, September 17, 2009 1:19 PM
INSTRUMENT AND CONTROL FUNCTIONS
EAU45440
TIP
The headlight comes on automatically
when the engine is started and stays on
until the key is turned to “OFF” or the
sidestand is moved down.
Main switch/steering lock
ON
OFF
3
OPEN
EAU10661
PUSH
OFF
All electrical systems are off. The key
can be removed.
LOC K
OPEN
To lock the steering and the centerstand
1
2
EWA10061
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.
TIP
The main switch/steering lock is
equipped with a keyhole cover. (See
page 3-2.)
EAU45430
ON
All electrical circuits are supplied with
power; the meter lighting, taillight, and
auxiliary light come on, and the engine
can be started. The key cannot be removed.
WARNING
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving.
Otherwise the electrical systems will
be switched off, which may result in
loss of control or an accident.
EAU49001
LOCK
The steering and the centerstand are
locked, and all electrical systems are
off. The key can be removed.
3-1
1. Push.
2. Turn.
1. Put the scooter on the centerstand.
2. Turn the handlebars all the way to
the left.
3. Push the key in from the “OFF” position, and then turn it to “LOCK”
while still pushing it.
4. Remove the key.
TIP
When the steering is locked, the centerstand is locked, and the scooter cannot
be taken off it.
chapter3 Page 2 Thursday, September 17, 2009 1:19 PM
INSTRUMENT AND CONTROL FUNCTIONS
To unlock the steering and the centerstand
1
EAUT2121
Keyhole cover
2
EAU45380
Indicator, indicator lights and
warning light
1
2
3
4
ON
F
OF
OP
EN
PU
SH
LOC
K
OP
3
EN
OIL
CHANGE
1. Push.
2. Turn.
Push the key in, and then turn it to
“OFF” while still pushing it.
To close the keyhole cover
Insert the key bow into the keyhole cover receptacle as shown, and then turn
the key to “SHUT” to close the cover.
To open the keyhole cover
Insert the key bow into the keyhole cover receptacle as shown, and then turn
the key to “OPEN” to open the cover.
1.
2.
3.
4.
Engine trouble warning light “
High beam indicator light “
”
Turn signal indicator light “
Oil change indicator
”
”
EAU11020
Turn signal indicator light “
”
This indicator light flashes when the
turn signal switch is pushed to the left or
right.
EAU11080
High beam indicator light “ ”
This indicator light comes on when the
high beam of the headlight is switched
on.
3-2
U4P7E2E0.book Page 3 Thursday, August 20, 2009 9:44 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU45401
Oil change indicator
This indicator changes from green to
red every 2000 km (1200 mi) to indicate
that the engine oil should be changed.
After changing the engine oil, push the
oil change indicator reset switch in with
the main switch key.
3
1
2
1. Oil change indicator
2. Oil change indicator reset switch
If the engine oil is changed before the
2000 km (1200 mi) interval, the indicator must be reset after the oil change for
the next periodic oil change to be indicated at the correct time. NOTICE: After 1000 km (600 mi) of operation, the
engine oil must be changed. [ECA10281]
EAUT1821
TIP
After resetting the oil change indicator
reset switch, the indicator changes
from red to green.
Speedometer unit
1
2
EAUT1934
Engine trouble warning light “ ”
This warning light flashes or stays on if
an electrical circuit monitoring the engine is not working correctly. If this occurs, have a Yamaha dealer check the
self-diagnosis system.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”. The warning light should come
on for a few seconds, and then go off.
If the warning light does not come on
initially when the key is turned to “ON”,
or if the warning light remains on, have
a Yamaha dealer check the electrical
circuit.
3-3
OIL
CHANGE
1. Speedometer
2. Odometer
The speedometer unit is equipped with
a speedometer and an odometer. The
speedometer shows the riding speed.
The odometer shows the total distance
traveled.
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INSTRUMENT AND CONTROL FUNCTIONS
EAU12092
Self-diagnosis device
EAU45630
Fuel gauge
This model is equipped with a self-diagnosis device for various electrical circuits.
If a problem is detected in any of those
circuits, the engine trouble warning light
will come on or flash. If this occurs,
have a Yamaha dealer check the vehicle.
1
To prevent engine damage, be sure
to consult a Yamaha dealer as soon
as possible if this occurs.
This model can be equipped with an
optional anti-theft alarm by a Yamaha
dealer. Contact a Yamaha dealer for
more information.
OIL
CHANGE
3
ECA11170
NOTICE
EAU12331
Anti-theft alarm (optional)
2
1. Fuel gauge
2. Red line
The fuel gauge indicates the amount of
fuel in the fuel tank. The needle moves
towards “E” (Empty) as the fuel level
decreases. When the needle reaches
the red line, refuel as soon as possible.
TIP
Turning the key to “OFF” cancels the
fuel gauge reading.
3-4
U4P7E2E0.book Page 5 Thursday, August 20, 2009 9:44 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU12348
Handlebar switches
Left
EAU12400
Dimmer switch “ / ”
Set this switch to “ ” for the high
beam and to “ ” for the low beam.
1
3
1. Dimmer switch “
/
”
2. Turn signal switch “
/
”
3. Horn switch “
”
Right
Turn signal switch “ / ”
To signal a right-hand turn, push this
switch to “ ”. To signal a left-hand
turn, push this switch to “ ”. When released, the switch returns to the center
position. To cancel the turn signal
lights, push the switch in after it has returned to the center position.
EAU12500
Horn switch “
”
Press this switch to sound the horn.
EAU12721
Start switch “ ”
With the sidestand up, push this switch
while applying the front or rear brake to
crank the engine with the starter. See
page 5-1 for starting instructions prior
to starting the engine.
1
1. Start switch “
1
EAU12460
2
3
EAU12900
Front brake lever
”
3-5
1. Front brake lever
The front brake lever is located on the
right handlebar grip. To apply the front
brake, pull this lever toward the handlebar grip.
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INSTRUMENT AND CONTROL FUNCTIONS
EAU12950
Rear brake lever
EAU45391
Fuel tank cap
EWA11091
WARNING
2
1
1
Make sure that the fuel tank cap is
properly closed after filling fuel.
Leaking fuel is a fire hazard.
3
1. Rear brake lever
The rear brake lever is located on the
left handlebar grip. To apply the rear
brake, pull this lever toward the handlebar grip.
1. Fuel tank cap lid
2. Fuel tank cap
To remove the fuel tank cap
1. Open the seat. (See page 3-8.)
2. Open the fuel tank cap lid.
3. Turn the fuel tank cap counterclockwise and pull it off.
To install the fuel tank cap
1. Insert the fuel tank cap into the
tank opening and turn it clockwise
until the “ ” marks on the cap
and tank are aligned.
2. Close the fuel tank cap lid.
3. Close the seat.
3-6
U4P7E2E0.book Page 7 Thursday, August 20, 2009 9:44 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU13221
1
Fuel
2
Make sure there is sufficient gasoline in
the tank.
EWA10881
ately. If gasoline spills on your skin,
wash with soap and water. If gasoline spills on your clothing, change
your clothes.
WARNING
3
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.
1. Before refueling, turn off the engine and be sure that no one is sitting on the vehicle. Never refuel
while smoking, or while in the vicinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters and
clothes dryers.
2. Do not overfill the fuel tank. When
refueling, be sure to insert the
pump nozzle into the fuel tank filler
hole. Stop filling when the fuel
reaches the bottom of the filler
tube. Because fuel expands when
it heats up, heat from the engine or
the sun can cause fuel to spill out
of the fuel tank.
EAU33520
Recommended fuel:
REGULAR UNLEADED GASOLINE ONLY
Fuel tank capacity:
5.5 L (1.45 US gal, 1.21 Imp.gal)
1. Fuel tank filler tube
2. Maximum fuel level
3. Wipe up any spilled fuel immediately. NOTICE: Immediately wipe
off spilled fuel with a clean, dry,
soft cloth, since fuel may deteriorate painted surfaces or plastic
parts. [ECA10071]
4. Be sure to securely close the fuel
tank cap.
EWA15151
WARNING
Gasoline is poisonous and can
cause injury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you should swallow
some gasoline or inhale a lot of gasoline vapor, or get some gasoline in
your eyes, see your doctor immedi3-7
ECA11400
NOTICE
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane number of
91 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand
or premium unleaded fuel. Use of unleaded fuel will extend spark plug life
and reduce maintenance costs.
U4P7E2E0.book Page 8 Thursday, August 20, 2009 9:44 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU13445
ECA10701
Catalytic converters
NOTICE
This vehicle is equipped with catalytic
converters in the exhaust system.
Use only unleaded gasoline. The use
of leaded gasoline will cause unrepairable damage to the catalytic
converter.
EWA10862
WARNING
The exhaust system is hot after operation. To prevent a fire hazard or
burns:
● Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.
● Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.
● Make sure that the exhaust system has cooled down before doing any maintenance work.
● Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up of
heat.
EAUT1503
Seat
To open the seat
1. Place the scooter on the centerstand.
2. Insert the key into the main switch,
and then turn it counterclockwise
to the first “OPEN” position. If the
main switch is in the “LOCK” position, turn the key counterclockwise
to the second “OPEN” position.
1
ON
OFF
ON
OFF
OPEN
OPEN
PUSH
PUSH
LOCK
LOCK
OPEN
OPEN
1
1. Seat open position
TIP
Do not push inward when turning the
key from “OFF” to “OPEN” or from
“LOCK” to “OPEN”.
3. Fold the seat up.
3-8
3
U4P7E2E0.book Page 9 Thursday, August 20, 2009 9:44 AM
INSTRUMENT AND CONTROL FUNCTIONS
To close the seat
1. Fold the seat down, and then push
it down to lock it in place.
2. Remove the key from the main
switch if the scooter will be left unattended.
3
EAU37481
Helmet holders
1
TIP
Make sure that the seat is properly secured before riding.
1. Helmet holder
The helmet holders are located under
the seat.
To secure a helmet to a helmet holder
1. Open the seat. (See page 3-8.)
2. Attach a helmet to a helmet holder,
and then securely close the seat.
WARNING! Never ride with a
helmet attached to the helmet
holder, since the helmet may hit
objects, causing loss of control
and possibly an accident. [EWA10161]
3-9
To release a helmet from a helmet
holder
Open the seat, remove the helmet from
the helmet holder, and then close the
seat.
U4P7E2E0.book Page 10 Thursday, August 20, 2009 9:44 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAUT1712
Storage compartments
●
Rear storage compartment
1
Front storage compartment
●
1
Since the storage compartment
may get wet while the scooter is
being washed, wrap any articles
stored in the compartment in a
plastic bag.
Do not keep anything valuable
or breakable in the storage compartment.
EWAT1051
WARNING
1. Rear storage compartment
●
The rear storage compartment is located under the seat. (See page 3-8.)
1. Front storage compartment
ECAT1030
EWA11191
WARNING
●
●
Do not exceed the load limit of
1.5 kg (3.3 lb) for the front storage compartment.
Do not exceed the maximum
load of 167 kg (368 lb) for the vehicle.
NOTICE
Keep the following points in mind
when using the storage compartment.
● Since the storage compartment
accumulates heat when exposed to the sun, do not store
anything susceptible to heat inside it.
● To avoid humidity from spreading through the storage compartment, wrap wet articles in a
plastic bag before storing them
in the compartment.
3-10
●
Do not exceed the load limit of 5
kg (11 lb) for the rear storage
compartment.
Do not exceed the maximum
load of 167 kg (368 lb) for the vehicle.
3
U4P7E2E0.book Page 11 Thursday, August 20, 2009 9:44 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU15112
Carrier
EAUT1072
Luggage hook
EWA10171
EWAT1031
WARNING
●
●
3
EAU15303
Sidestand
WARNING
Do not exceed the load limit of 5
kg (11 lb) for the carrier.
Do not exceed the maximum
load of 167 kg (368 lb) for the vehicle.
●
●
Do not exceed the load limit of
1.0 kg (2.2 lb) for the luggage
hook.
Do not exceed the maximum
load of 167 kg (368 lb) for the vehicle.
1
1
1. Sidestand
1
The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.
TIP
The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See page 3-12 for an explanation of
the ignition circuit cut-off system.)
1. Carrier
1. Luggage hook
EWA10240
WARNING
The vehicle must not be ridden with
the sidestand down, or if the sidestand cannot be properly moved up
3-11
U4P7E2E0.book Page 12 Thursday, August 20, 2009 9:44 AM
INSTRUMENT AND CONTROL FUNCTIONS
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
Yamaha’s ignition circuit cut-off
system has been designed to assist
the operator in fulfilling the responsibility of raising the sidestand before starting off. Therefore, check
this system regularly as described
below and have a Yamaha dealer repair it if it does not function properly.
EAUT1095
Ignition circuit cut-off system
Check the operation of the sidestand
switch according to the following procedure.
3
3-12
U4P7E2E0.book Page 13 Thursday, August 20, 2009 9:44 AM
INSTRUMENT AND CONTROL FUNCTIONS
Turn the key on.
WARNING
• The vehicle must be placed on the center-
3
Put the sidestand up.
stand during this inspection.
• If a malfunction is noted, have a Yamaha
dealer check the system before riding.
Push the start switch while applying
either of the brake levers. The engine will
start.
Put the sidestand down.
If the engine stalls:
The sidestand switch is OK.
3-13
U4P7E2E0.book Page 1 Thursday, August 20, 2009 9:44 AM
FOR YOUR SAFETY – PRE-OPERATION CHECKS
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
EWA11151
WARNING
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
ITEM
CHECKS
PAGE
Fuel
• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
3-7
Engine oil
• Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.
6-9
Final transmission oil
• Check vehicle for oil leakage.
6-11
Front brake
•
•
•
•
•
•
•
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
6-18, 6-19
Rear brake
•
•
•
•
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.
6-17, 6-18
4-1
4
U4P7E2E0.book Page 2 Thursday, August 20, 2009 9:44 AM
FOR YOUR SAFETY – PRE-OPERATION CHECKS
ITEM
CHECKS
PAGE
Throttle grip
• Make sure that operation is smooth.
• Check cable free play.
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.
6-14, 6-20
Control cables
• Make sure that operation is smooth.
• Lubricate if necessary.
Wheels and tires
•
•
•
•
Brake levers
• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
6-21
Centerstand, sidestand
• Make sure that operation is smooth.
• Lubricate pivots if necessary.
6-21
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.
—
Instruments, lights, signals
and switches
• Check operation.
• Correct if necessary.
—
Sidestand switch
• Check operation of ignition circuit cut-off system.
• If system is not working correctly, have Yamaha dealer check vehicle.
4
6-20
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
4-2
6-15, 6-17
3-11
U4P7E2E0.book Page 1 Thursday, August 20, 2009 9:44 AM
OPERATION AND IMPORTANT RIDING POINTS
EAU15951
EAU45310
EAU45422
Starting the engine
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
EWA10271
WARNING
Failure to familiarize yourself with
the controls can lead to loss of control, which could cause an accident
or injury.
ECA10250
TIP
This model is equipped with a lean angle sensor to stop the engine in case of
a turnover. To start the engine after a
turnover, be sure to turn the main
switch to “OFF” and then to “ON”. Failing to do so will prevent the engine from
starting even though the engine will
crank when pushing the start switch.
5-1
NOTICE
See page 5-4 for engine break-in instructions prior to operating the vehicle for the first time.
In order for the ignition circuit cut-off
system to enable starting, the sidestand must be up.
See page 3-12 for more information.
1. Turn the key to “ON”.
2. Close the throttle completely.
3. Start the engine by pushing the
start switch while applying the front
or rear brake. NOTICE: For maximum engine life, never accelerate hard when the engine is
cold! [ECA11041]
If the engine fails to start, release
the start switch, wait a few seconds, and then try again. Each
starting attempt should be as short
as possible to preserve the battery. Do not crank the engine more
than 5 seconds on any one attempt.
5
U4P7E2E0.book Page 2 Thursday, August 20, 2009 9:44 AM
OPERATION AND IMPORTANT RIDING POINTS
EAU45091
1
2
3
Starting off
EAU16780
Acceleration and deceleration
1. While pulling the rear brake lever
with your left hand and holding the
grab bar with your right hand, push
the scooter off the centerstand.
(b)
1
(a)
1. Rear brake lever
2. Start switch
3. Front brake lever
ZAUM0199
The speed can be adjusted by opening
and closing the throttle. To increase the
speed, turn the throttle grip in direction
(a). To reduce the speed, turn the throttle grip in direction (b).
5
1. Grab bar
2. Sit astride the seat, and then adjust the rear view mirrors.
3. Switch the turn signals 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 signals off.
5-2
U4P7E2E0.book Page 3 Thursday, August 20, 2009 9:44 AM
OPERATION AND IMPORTANT RIDING POINTS
EAU16793
EAU16820
Braking
Tips for reducing fuel consumption
EWA10300
WARNING
●
●
●
●
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:
● Avoid high engine speeds during
acceleration.
● Avoid high engine speeds with no
load on the engine.
● Turn the engine off instead of letting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
Avoid braking hard or suddenly
(especially when leaning over to
one side), otherwise the scooter
may skid or overturn.
Railroad crossings, streetcar
rails, iron plates on road construction sites, and manhole
covers become extremely slippery when wet. Therefore, slow
down when approaching such
areas and cross them with caution.
Keep in mind that braking on a
wet road is much more difficult.
Ride slowly down a hill, as braking downhill can be very difficult.
1. Close the throttle completely.
2. Apply both front and rear brakes
simultaneously while gradually increasing the pressure.
5-3
5
U4P7E2E0.book Page 4 Thursday, August 20, 2009 9:44 AM
OPERATION AND IMPORTANT RIDING POINTS
EAU16830
Engine break-in
5
There is never a more important period
in the life of your engine than the period
between 0 and 1000 km (600 mi). For
this reason, you should read the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1000 km (600 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throttle operation or any condition that might
result in engine overheating must be
avoided.
the engine oil and final transmission
oil, and to clean the oil strainer.
[ECA16501]
1000 km (600 mi) and beyond
The vehicle can now be operated normally.
EAU17213
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10311
WARNING
ECA10270
●
NOTICE
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
●
●
EAU45581
0–150 km (0–90 mi)
Avoid prolonged operation above 1/3
throttle.
150–500 km (90–300 mi)
Avoid prolonged operation above 1/2
throttle.
500–1000 km (300–600 mi)
Avoid prolonged operation above 3/4
throttle. NOTICE: After 1000 km (600
mi) of operation, be sure to change
5-4
Since the engine and exhaust
system can become very hot,
park in a place where pedestrians or children are not likely to
touch them and be burned.
Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn, increasing the
risk of a fuel leak and fire.
Do not park near grass or other
flammable materials which
might catch fire.
U4P7E2E0.book Page 1 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU17241
EWA15121
WARNING
Periodic inspection, adjustment, and lubrication will keep your vehicle in the
safest and most efficient condition possible. Safety is an obligation of the vehicle owner/operator. The most important
points of vehicle inspection, adjustment, and lubrication are explained on
the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a general guide under normal riding conditions. However, depending on the
weather, terrain, geographical location,
and individual use, the maintenance intervals may need to be shortened.
Turn off the engine when performing
maintenance
unless
otherwise
specified.
● A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
● Running the engine while servicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more information about carbon monoxide.
EWA10321
WARNING
Failure to properly maintain the vehicle or performing maintenance activities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle service, have a Yamaha dealer perform
service.
6-1
6
U4P7E2E0.book Page 2 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU46871
TIP
●
●
●
The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.
From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi).
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
EAU46920
Periodic maintenance chart for the emission control system
ODOMETER READING
NO.
6
ITEM
1 * Fuel line
2
Spark plug
CHECK OR MAINTENANCE JOB
1000 km
(600 mi)
6000 km
(3500 mi)
12000 km
(7000 mi)
18000 km
(10500 mi)
24000 km
(14000 mi)
• Check fuel hoses for cracks or
damage.
√
√
√
√
• Check condition.
• Clean and regap.
√
3 * Valves
4 * Fuel injection
5 *
Air induction system
• Check valve clearance.
• Adjust.
• Check engine idle speed.
√
• Check the air cut-off valve, reed
valve, and hose for damage.
• Replace any damaged parts if
necessary.
6-2
√
√
√
• Replace.
ANNUAL
CHECK
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
U4P7E2E0.book Page 3 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU17717
General maintenance and lubrication chart
ODOMETER READING
NO.
ITEM
1 * Air filter element
2
V-belt case air filter
element
3 * Front brake
CHECK OR MAINTENANCE JOB
1000 km
(600 mi)
6000 km
(3500 mi)
• Clean.
√
4 * Rear brake
√
√
√
√
√
√
√
√
√
√
√
√
Whenever worn to the limit
√
√
√
√
Whenever worn to the limit
√
• Check for cracks or damage.
• Replace.
√
√
Every 4 years
6 * Wheels
• Check runout and for damage.
√
√
√
√
7 * Tires
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
√
√
√
√
8 * Wheel bearings
• Check bearing for looseness or
damage.
√
√
√
√
√
√
√
√
9 * Steering bearings
• Check bearing play and steering
for roughness.
ANNUAL
CHECK
√
• Replace brake shoes.
5 * Brake hose
24000 km
(14000 mi)
√
• Replace brake pads.
• Check operation and adjust brake
lever free play.
18000 km
(10500 mi)
√
• Replace.
• Check operation, fluid level and
vehicle for fluid leakage.
12000 km
(7000 mi)
√
• Lubricate with lithium-soap-based
grease.
Every 24000 km (14000 mi)
6-3
√
6
U4P7E2E0.book Page 4 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
ODOMETER READING
NO.
ITEM
10 * Chassis fasteners
CHECK OR MAINTENANCE JOB
1000 km
(600 mi)
ANNUAL
CHECK
6000 km
(3500 mi)
12000 km
(7000 mi)
18000 km
(10500 mi)
24000 km
(14000 mi)
• Make sure that all nuts, bolts and
screws are properly tightened.
√
√
√
√
√
11
Front brake lever
pivot shaft
• Lubricate with silicone grease.
√
√
√
√
√
12
Rear brake lever
pivot shaft
• Lubricate with lithium-soap-based
grease.
√
√
√
√
√
13
Sidestand, centerstand
• Check operation.
• Lubricate with lithium-soap-based
grease.
√
√
√
√
√
√
√
√
√
√
√
14 * Sidestand switch
• Check operation.
15 * Front fork
• Check operation and for oil leakage.
√
√
√
√
√
√
√
√
6
16 *
Shock absorber assembly
• Check operation and shock absorber for oil leakage.
17
Engine oil
• Change. (See page 6-9.)
• Check oil level and vehicle for oil
leakage.
√
• Clean.
√
18 * Engine oil strainer
19
Final transmission
oil
• Check vehicle for oil leakage.
√
• Change.
√
20 * V-belt
• Replace.
Front and rear brake
21 *
switches
• Check operation.
22
Moving parts and
cables
Every 2000 km (1200 mi)
√
√
√
√
√
√
Every 12000 km (7000 mi)
√
• Lubricate.
6-4
√
√
√
√
√
√
√
√
√
√
U4P7E2E0.book Page 5 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
ODOMETER READING
NO.
ITEM
Throttle grip hous23 *
ing and cable
24 *
Lights, signals and
switches
CHECK OR MAINTENANCE JOB
1000 km
(600 mi)
• Check operation and free play.
• Adjust the throttle cable free play
if necessary.
• Lubricate the throttle grip housing
and cable.
• Check operation.
• Adjust headlight beam.
√
ANNUAL
CHECK
6000 km
(3500 mi)
12000 km
(7000 mi)
18000 km
(10500 mi)
24000 km
(14000 mi)
√
√
√
√
√
√
√
√
√
√
EAU45610
TIP
●
●
●
Air filter
• This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.
V-belt case air filter
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
• Replace the brake hose every four years and if cracked or damaged.
6-5
6
U4P7E2E0.book Page 6 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU18712
Removing and installing cowlings and panels
1
The cowlings and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each time
a cowling or panel needs to be removed and installed.
1
1
1. Screw
1
2
6
3
4
1. Screw
To install the cowling
Place the cowling in the original position, and then install the screws.
EAU45470
1
Cowling B
1.
2.
3.
4.
To remove the cowling
1. Remove the screws, and then pull
the cowling off as shown.
Cowling A
Cowling B
Panel A
Panel B
1. Screw
2. Disconnect the headlight coupler,
and the auxiliary light lead coupler.
EAU18852
Cowling A
To remove the cowling
Remove the screws, and then pull the
cowling off as shown.
6-6
U4P7E2E0.book Page 7 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
1
1
2
1
1. Headlight coupler
2. Auxiliary light lead coupler
1. Screw
To install the cowling
1. Connect the headlight coupler,
and the auxiliary light lead coupler.
2. Place the cowling in the original
position, and then install the
screws.
EAU19281
1. Floorboard mat
To install the panel
Place the panel in the original position,
and then install the screw.
2. Remove the screws, and then pull
the panel off as shown.
1
6
EAU45450
Panel B
To remove the panel
1. Pull up the floorboard mat.
Panel A
To remove the panel
Remove the screw, and then pull the
panel off as shown.
1. Screw
To install the panel
1. Place the panel in the original position, and then install the screws.
2. Place the floorboard mat in the
original position.
6-7
U4P7E2E0.book Page 8 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU45590
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic maintenance and lubrication chart. In addition,
the condition of the spark plug can reveal the condition of the engine.
6
To remove the spark plug
1. Place the vehicle on the centerstand.
2. Remove panel A. (See page 6-6.)
3. Remove the spark plug cap.
4. Remove the spark plug as shown,
using the spark plug wrench,
which is located in the rear storage
compartment. (See page 3-10.)
1
TIP
If the spark plug shows a distinctly different color, the engine could be operating improperly. Do not attempt to
diagnose such problems yourself. Instead, have a Yamaha dealer check
the vehicle.
2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
1. Spark plug wrench
1
Specified spark plug:
NGK/CR7E
To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if necessary, adjust the gap to specification.
1. Spark plug wrench
To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
6-8
U4P7E2E0.book Page 9 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU45482
TIP
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.
1. Spark plug gap
4. Install the spark plug cap.
5. Install the panel.
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tighten it to the specified torque.
Engine oil
The engine oil level should be checked
before each ride. In addition, the oil
must be changed at the intervals specified in the periodic maintenance and
lubrication chart.
The engine oil must also be changed at
the initial 1000 km (600 mi) and when
the oil change indicator color changes
from green to red. The oil change indicator must be reset after the initial 1000
km (600 mi). (See page 3-2 for reset
procedures.)
To check the engine oil level
1. Place the vehicle on the centerstand. A slight tilt to the side can
result in a false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil settles, remove the oil filler cap, wipe
the engine oil dipstick clean, insert
it back into the oil filler hole (without screwing it in), and then remove it again to check the oil level.
Tightening torque:
Spark plug:
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
6-9
6
U4P7E2E0.book Page 10 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
TIP
The engine oil should be between the
tip of the dipstick and maximum level
mark.
2
3
4
6
1.
2.
3.
4.
1
Engine oil filler cap
Engine oil dipstick
Maximum level mark
Tip of the engine oil dipstick
4. If the engine oil is not between the
tip of the dipstick and the maximum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Insert the engine oil dipstick into
the oil filler hole, and then tighten
the oil filler cap.
To change the engine oil
1. Place the vehicle on the centerstand.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Place an oil pan under the engine
to collect the used oil.
4. Remove the engine oil filler cap,
and then remove the engine oil
drain bolt and its gasket to drain
the oil from the crankcase.
Tightening torque:
Engine oil drain bolt
20 Nm (2.0 m·kgf, 14 ft·lbf)
6. Refill with the specified amount of
the recommended engine oil, and
then install and tighten the engine
oil filler cap.
Recommended engine oil:
See page 8-1.
Oil quantity:
1.00 L (1.06 US qt, 0.88 Imp.qt)
2
ECA11670
NOTICE
●
1
1
1. Engine oil drain bolt
2. Gasket
5. Install the engine oil drain bolt and
its new gasket, and then tighten
the bolt to the specified torque.
6-10
●
Do not use oils with a diesel
specification of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
Be sure no foreign material enters the crankcase.
7. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, immediately turn the engine off and
check for the cause.
U4P7E2E0.book Page 11 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
8. Turn the engine off, and then
check the oil level and correct it if
necessary.
9. Reset the oil change indicator.
(See page 3-2 for reset procedures.)
TIP
If the engine oil is changed before the
oil change indicator color changes from
green to red (i.e. before the periodic oil
change interval has been reached), the
oil change indicator must be reset after
the oil change for the next periodic oil
change to be indicated at the correct
time.
EAU20065
Final transmission oil
The final transmission case must be
checked for oil leakage before each
ride. If any leakage is found, have a
Yamaha dealer check and repair the
scooter. In addition, the final transmission oil must be changed as follows at
the intervals specified in the periodic
maintenance and lubrication chart.
1. Start the engine, warm up the final
transmission oil by riding the
scooter for several minutes, and
then stop the engine.
2. Place the scooter on the centerstand.
3. Place an oil pan under the final
transmission case to collect the
used oil.
4. Remove the final transmission oil
filler cap and its O-ring from the final transmission case.
5. Remove the final transmission oil
drain bolt and its gasket to drain
the oil from the final transmission
case.
6-11
1
1
2
1. Final transmission oil filler cap
2. O-ring
6. Install the final transmission oil
drain bolt and its new gasket, and
then tighten the bolt to the specified torque.
2
1
1. Final transmission oil drain bolt
2. Gasket
1
6
U4P7E2E0.book Page 12 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU45492
Tightening torque:
Final transmission oil drain bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
7. Refill with the specified amount of
the recommended final transmission oil. WARNING! Make sure
that no foreign material enters
the final transmission case.
Make sure that no oil gets on the
tire or wheel. [EWA11311]
6
Recommended final transmission
oil:
See page 8-1.
Oil quantity:
0.13 L (0.14 US qt, 0.11 Imp.qt)
8. Install the final transmission oil filler cap and its new O-ring, and then
tighten the oil filler cap.
9. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
Air filter and V-belt case air filter elements
The air filter element should be replaced and the V-belt case air filter element should be cleaned at the intervals
specified in the periodic maintenance
and lubrication chart. Service the air filter elements more frequently if you are
riding in unusually wet or dusty areas.
The air filter check hoses must be frequently checked and cleaned if necessary.
2
1
2
1. Air filter case cover
2. Screw
3. Pull the air filter element out.
1
Replacing the air filter element
1. Place the scooter on the centerstand.
2. Remove the air filter case cover by
removing the screws.
1. Air filter element
4. Insert a new air filter element into
the air filter case. NOTICE: Make
sure that the air filter element is
properly seated in the air filter
case. The engine should never
6-12
U4P7E2E0.book Page 13 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
be operated without the air filter
element installed, otherwise the
piston(s) and/or cylinder(s) may
become
excessively
worn.
[ECA10481]
5. Install the air filter case cover by installing the screws.
Cleaning the V-belt case air filter element
1. Place the scooter on the centerstand.
2. Remove the screws, and then pull
the V-belt case air filter element
cover outward and away from Vbelt case.
1
2
Cleaning the air filter check hoses
1
1
2
3
1. Air filter check hose
2. Clamp
3. Air filter check hose plug
1. Check the hoses on the rear side
of the air filter case for accumulated dirt or water.
2. If dirt or water is visible in the air filter check hoses, remove the
clamps from them, and then remove the plugs to drain the hoses.
1. V-belt case air filter element holder
2. Screw
2
1. V-belt case air filter element cover
2. Screw
3. Remove the V-belt case air filter
element holder by removing the
screw.
6-13
4. Pull the V-belt case air filter element out, and then clean it with
solvent. After cleaning, remove the
remaining solvent by squeezing
the element. WARNING! Use
only a dedicated parts cleaning
solvent. To avoid the risk of fire
or explosion, do not use gasoline or solvents with a low flash
point. [EWA10431] NOTICE: To avoid
damaging the air filter element,
handle it gently and carefully,
and do not twist it. [ECA10521]
6
U4P7E2E0.book Page 14 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU21382
Recommended oil:
Yamaha foam air filter oil or other
quality foam air filter oil
6. Insert the element into the V-belt
case.
7. Install the air filter element holder
by installing the screw.
8. Install the air filter element cover
by installing the screws.
Checking the throttle cable
free play
1
ZAUM0051
1. Throttle cable free play
The throttle cable free play should measure 3.0–5.0 mm (0.12–0.20 in) at the
throttle grip. Periodically check the
throttle cable free play and, if necessary, have a Yamaha dealer adjust it.
6
1
1. V-belt case air filter element
5. Apply oil of the recommended type
to the entire surface of the sponge
material, and then squeeze the excess oil out.
TIP
The air filter element should be wet but
not dripping.
6-14
U4P7E2E0.book Page 15 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU21401
EAU33601
Valve clearance
Tires
The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
To maximize the performance, durability, and safe operation of your vehicle,
note the following points regarding the
specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
EWA10501
WARNING
Operation of this vehicle with improper tire pressure may cause severe injury or death from loss of
control.
● The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
● The tire air pressure must be adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, cargo, and accessories approved
for this model.
6-15
Tire air pressure (measured on cold
tires):
0–83 kg (0–183 lb):
Front:
175 kPa (1.75 kgf/cm², 25 psi)
Rear:
200 kPa (2.00 kgf/cm², 29 psi)
83–167 kg (183–368 lb):
Front:
175 kPa (1.75 kgf/cm², 25 psi)
Rear:
250 kPa (2.50 kgf/cm², 36 psi)
Maximum load*:
167 kg (368 lb)
* Total weight of rider, passenger, cargo and accessories
EWA10511
WARNING
Never overload your vehicle. Operation of an overloaded vehicle could
cause an accident.
6
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PERIODIC MAINTENANCE AND ADJUSTMENT
Tire inspection
1. Tire sidewall
2. Tire tread depth
6
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer replace the tire immediately.
Tire information
This model is equipped with tubeless
tires.
After extensive tests, only the tires listed below have been approved for this
model by Yamaha Motor Co., Ltd.
Front tire:
Size:
100/90-10 56J
Manufacturer/model:
CHENG SHIN/C-922
Rear tire:
Size:
100/90-10 56J
Manufacturer/model:
CHENG SHIN/C-940
EWA10470
WARNING
●
Minimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
TIP
The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
●
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehicle with excessively worn tires
decreases riding stability and
can lead to loss of control.
The replacement of all wheel
and brake related parts, including the tires, should be left to a
6-16
Yamaha dealer, who has the
necessary professional knowledge and experience.
U4P7E2E0.book Page 17 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU21960
Cast wheels
To maximize the performance, durability, and safe operation of your vehicle,
note the following points regarding the
specified wheels.
● The wheel rims should be checked
for cracks, bends or warpage before each ride. If any damage is
found, have a Yamaha dealer replace the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.
● 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.
● Ride at moderate speeds after
changing a tire since the tire surface must first be “broken in” for it
to develop its optimal characteristics.
EAUT1221
Checking the front brake lever
free play
1
EAU22170
Adjusting the rear brake lever
free play
1
1. Front brake lever free play
1. Rear brake lever free play
The brake lever free play should measure 2.0–5.0 mm (0.08–0.20 in) as
shown. Periodically check the brake lever free play and, if necessary, have a
Yamaha dealer check the brake system.
The brake lever free play should measure 10.0–20.0 mm (0.39–0.79 in) as
shown. Periodically check the brake lever free play and, if necessary, adjust it
as follows.
To increase the brake lever free play,
turn the adjusting nut at the brake shoe
plate in direction (a). To decrease the
brake lever free play, turn the adjusting
nut in direction (b).
EWA10641
WARNING
An incorrect brake lever free play indicates a hazardous condition in the
brake system. Do not operate the vehicle until the brake system has
been checked or repaired by a
Yamaha dealer.
6-17
6
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PERIODIC MAINTENANCE AND ADJUSTMENT
Checking the front brake pads
and rear brake shoes
indicator grooves have almost disappeared, have a Yamaha dealer replace
the brake pads as a set.
The front brake pads and the rear brake
shoes must be checked for wear at the
intervals specified in the periodic maintenance and lubrication chart.
Rear brake shoes
EAU22380
(a)
(b)
1
EAU22540
EAU22430
Front brake pads
1. Adjusting nut
2
EWA10650
WARNING
6
1
If proper adjustment cannot be obtained as described, have a Yamaha
dealer make this adjustment.
1. Brake shoe wear indicator
2. Brake shoe wear limit line
1
1. Brake pad wear indicator groove
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
6-18
The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to disassemble the brake. To check the
brake shoe wear, check the position of
the wear indicator while applying the
brake. If a brake shoe has worn to the
point that the wear indicator reaches
the wear limit line, have a Yamaha
dealer replace the brake shoes as a
set.
U4P7E2E0.book Page 19 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU37001
Checking the front brake fluid
level
●
●
1
When checking the fluid level,
make sure that the top of the master cylinder is level by turning the
handlebars.
Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking performance.
●
●
Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid
immediately.
As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the
brake fluid level goes down suddenly, have a Yamaha dealer
check the cause.
Recommended brake fluid:
DOT 4
1. Minimum level mark
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 the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:
TIP
If DOT 4 is not available, DOT 3 can be
used.
●
●
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
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.
6-19
6
U4P7E2E0.book Page 20 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU22721
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenance
and lubrication chart. In addition, have
the oil seals of the brake master cylinder and caliper as well as the brake
hose replaced at the intervals listed below or whenever they are damaged or
leaking.
● Oil seals: Replace every two
years.
● Brake hose: Replace every four
years.
6
EAU23101
EAU23112
Checking and lubricating the
cables
Checking and lubricating the
throttle grip and cable
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING! Damage to the outer
sheath may interfere with proper cable operation and will cause the inner cable to rust. Replace a
damaged cable as soon as possible
to prevent unsafe conditions. [EWA10721]
The operation of the throttle grip should
be checked before each ride. In addition, the cable should be lubricated by a
Yamaha dealer at the intervals specified in the periodic maintenance chart.
Recommended lubricant:
Engine oil
6-20
U4P7E2E0.book Page 21 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU43641
Lubricating the front and rear
brake levers
Front brake lever
EAU23213
Recommended lubricants:
Front brake lever:
Silicone grease
Rear brake lever:
Lithium-soap-based grease
Checking and lubricating the
centerstand and sidestand
The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-tometal contact surfaces should be lubricated if necessary.
Rear brake lever
EWA10741
WARNING
If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or repair it. Otherwise, the centerstand or
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
The pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic maintenance and lubrication chart.
6-21
6
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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU23272
Recommended lubricant:
Lithium-soap-based grease
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic maintenance and lubrication chart.
To check the condition
Check the inner tubes for scratches,
damage and excessive oil leakage.
ECA10590
6
To check the operation
1. Place the vehicle on a level surface and hold it in an upright position. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over. [EWA10751]
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
6-22
NOTICE
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or repair it.
U4P7E2E0.book Page 23 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU45511
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication
chart.
1. Place the vehicle on the centerstand. WARNING! To avoid injury, securely support the vehicle
so there is no danger of it falling
over. [EWA10751]
2. Hold the lower ends of the front
fork legs and try to move them forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
EAU23291
Checking the wheel bearings
EAUT1857
Battery
2
3
1
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.
1. Battery
2. Positive battery lead (red)
3. Negative battery lead (black)
This model is equipped with a VRLA
(Valve Regulated Lead Acid) battery.
There is no need to check the electrolyte or to add distilled water. However,
the battery lead connections need to be
checked and, if necessary, tightened.
TIP
The battery is located behind panel B.
(See page 6-6.)
6-23
6
U4P7E2E0.book Page 24 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EWA10760
WARNING
●
6
●
Electrolyte is poisonous and
dangerous since it contains sulfuric acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and always shield your eyes when
working near batteries. In case
of contact, administer the following FIRST AID.
• EXTERNAL: Flush with plenty
of water.
• INTERNAL: Drink large quantities of water or milk and immediately call a physician.
• EYES: Flush with water for 15
minutes and seek prompt
medical attention.
Batteries produce explosive hydrogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and provide sufficient ventilation when
charging it in an enclosed
space.
●
battery, be sure the key is
turned to “OFF”, then disconnect the negative lead before
disconnecting the positive lead.
KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF
CHILDREN.
To charge the battery
Have a Yamaha dealer charge the battery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the vehicle is equipped with optional
electrical accessories.
ECA16520
NOTICE
To charge a VRLA (Valve Regulated
Lead Acid) battery, a special (constant-voltage) battery charger is required. Using a conventional battery
charger will damage the battery. If
you do not have access to a constant-voltage battery charger, have a
Yamaha dealer charge your battery.
To store the battery
1. If the vehicle will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
NOTICE: When removing the
6-24
[ECA16302]
2. If the battery will be stored for more
than two months, check it at least
once a month and fully charge it if
necessary.
3. Fully charge the battery before installation.
4. Before installation, make sure that
the battery leads are properly connected to the battery terminals.
ECAT1053
NOTICE
●
●
Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.
After installing the battery, be
sure to turn the main switch
from “ON” to “OFF” three times
in 3 seconds intervals to initialize the idle speed control system.
U4P7E2E0.book Page 25 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAUT2023
Replacing the fuse
1
2
After removing and installing
the main fuse, be sure to turn
the main switch from “ON” to
“OFF” three times in 3 seconds
intervals to initialize the idle
speed control system. [ECAT1062]
Specified fuse:
15.0 A
1. Fuse
2. Spare fuse
The fuse holder is located beside the
battery. Remove panel B to access the
fuse. (See page 6-6.)
If the fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
all electrical circuits.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage. WARNING! Do not
use a fuse of a higher amperage
rating than recommended to
avoid causing extensive damage to the electrical system and
possibly a fire. [EWA15131] NOTICE:
3. Turn the key to “ON” and turn on
the electrical circuits to check if the
devices operate.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAU45503
Replacing the headlight bulb
This model is equipped with a quartz
bulb headlight. If the headlight bulb
burns out, replace it as follows.
ECA10660
NOTICE
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely affected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with alcohol or thinner.
1. Do not touch the glass part of the bulb.
1. Place the vehicle on the centerstand.
6-25
6
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PERIODIC MAINTENANCE AND ADJUSTMENT
2. Remove cowling B. (See page
6-6.)
3. Remove the headlight bulb cover.
1
5. Place a new headlight bulb into position, and then install the bulb
holder by turning the holder clockwise.
6. Install the headlight bulb cover.
7. Install the cowling.
8. Have a Yamaha dealer adjust the
headlight beam if necessary.
1. Headlight bulb cover
6
4. Remove the headlight bulb holder
by turning it counterclockwise, and
then remove the burnt-out bulb
from the headlight unit.
EAUT1262
Replacing a front turn signal
light bulb
ECA10670
NOTICE
It is advisable to have a Yamaha
dealer perform this job.
1. Place the scooter on the centerstand.
2. Remove cowling A. (See page
6-6.)
3. Remove the socket (together with
the bulb) by turning it counterclockwise.
1
1
2
1. Turn signal light bulb socket
4. Remove the burnt-out bulb by
pushing it in and turning it counterclockwise.
1. Headlight bulb holder
2. Headlight bulb
6-26
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PERIODIC MAINTENANCE AND ADJUSTMENT
5. Insert a new bulb into the socket,
push it in, and then turn it clockwise until it stops.
6. Install the socket (together with the
bulb) by turning it clockwise.
7. Install the cowling.
EAU37741
EAU45462
Rear turn signal light and
tail/brake light
Replacing the auxiliary light
bulb
If a rear turn signal light or the tail/brake
light does not come on, have a Yamaha
dealer check its electrical circuit or replace the bulb.
If the auxiliary light bulb burns out, replace it as follows.
1. Place the vehicle on the centerstand.
2. Remove cowling A. (See page
6-6.)
3. Remove the auxiliary light socket
(together with the bulb) by pulling it
out.
6
1 2
1. Auxiliary light bulb
2. Auxiliary light bulb socket
4. Remove the burnt-out bulb by pulling it out.
5. Insert a new bulb into the socket.
6-27
U4P7E2E0.book Page 28 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
6. Install the auxiliary light socket (together with the bulb) by pushing it
in.
7. Install the cowling.
6
EAU25861
Troubleshooting
Although Yamaha scooters receive a
thorough inspection before shipment
from the factory, trouble may occur during operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems yourself. However, should your scooter require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the scooter properly.
Use only genuine Yamaha replacement parts. Imitation parts may look like
Yamaha parts, but they are often inferior, have a shorter service life and can
lead to expensive repair bills.
EWA15141
WARNING
When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the area, including pilot lights from water
6-28
heaters or furnaces. Gasoline or
gasoline vapors can ignite or explode, causing severe injury or
property damage.
U4P7E2E0.book Page 29 Thursday, August 20, 2009 9:44 AM
PERIODIC MAINTENANCE AND ADJUSTMENT
EAUT1981
Troubleshooting chart
1. Fuel
There is enough fuel.
Check the compression.
There is no fuel.
Supply fuel.
There is compression.
Check the ignition.
There is no compression.
Have a Yamaha dealer
check the vehicle.
Check the fuel level in
the fuel tank.
The engine does not start.
Check the compression.
2. Compression
Operate the electric starter.
3. Ignition
Wet
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Operate the electric starter.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the battery.
6
Remove the spark plug
and check the electrodes.
Dry
4. Battery
The engine turns over
quickly.
The battery is good.
The engine turns over
slowly.
Check the battery lead connections,
and charge the battery if necessary.
Operate the electric starter.
6-29
The engine does not start.
Have a Yamaha dealer
check the vehicle.
U4P7E2E0.book Page 1 Thursday, August 20, 2009 9:44 AM
SCOOTER CARE AND STORAGE
EAU37833
Matte color caution
ECA15192
NOTICE
Some models are equipped with
matte colored finished parts. Be
sure to consult a Yamaha dealer for
advice on what products to use before cleaning the vehicle. Using a
brush, harsh chemical products or
cleaning compounds when cleaning
these parts will scratch or damage
their surface. Wax also should not
be applied to any matte colored finished parts.
7
ucts onto seals, gaskets and wheel
axles. Always rinse the dirt and degreaser off with water.
EAU26094
Care
While the open design of a scooter reveals the attractiveness of the technology, it also makes it more vulnerable.
Rust and corrosion can develop even if
high-quality components are used. A
rusty exhaust pipe may go unnoticed
on a car, however, it detracts from the
overall appearance of a scooter. Frequent and proper care does not only
comply with the terms of the warranty,
but it will also keep your scooter looking
good, extend its life and optimize its
performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
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
brush, but never apply such prod7-1
Cleaning
ECA10783
NOTICE
●
●
Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse
the area off with water, immediately dry it, and then apply a corrosion protection spray.
Improper cleaning can damage
plastic parts (such as cowlings,
panels, windshields, headlight
lenses, meter lenses, etc.) and
the mufflers. Use only a soft,
clean cloth or sponge with water to clean plastic. However, if
the plastic parts cannot be thoroughly cleaned with water, diluted mild detergent with water
may be used. Be sure to rinse
U4P7E2E0.book Page 2 Thursday, August 20, 2009 9:44 AM
SCOOTER CARE AND STORAGE
●
●
●
off any detergent residue using
plenty of water, as it is harmful
to plastic parts.
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.
Do not use high-pressure washers or steam-jet cleaners since
they cause water seepage and
deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes),
electric components (couplers,
connectors,
instruments,
switches and lights), breather
hoses and vents.
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 that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing
compound
after
washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on the
roads during winter are extremely corrosive in combination with water, carry
out the following steps after each ride in
the rain, near the sea or on saltsprayed roads.
7-2
TIP
Salt sprayed on roads in the winter may
remain well into spring.
1. Clean the scooter with cold water
and a mild detergent after the engine has cooled down. NOTICE:
Do not use warm water since it
increases the corrosive action
of the salt. [ECA10791]
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the scooter with a chamois or
an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stainlesssteel parts, including the exhaust
system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.)
7
U4P7E2E0.book Page 3 Thursday, August 20, 2009 9:44 AM
SCOOTER CARE AND STORAGE
3. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal,
including chrome- and nickel-plated, 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 or covering it.
ECA10800
●
●
●
EAU36561
Storage
NOTICE
Apply spray oil and wax sparingly and make sure to wipe off
any excess.
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
Avoid using abrasive polishing
compounds as they will wear
away the paint.
Short-term
Always store your scooter in a cool, dry
place and, if necessary, protect it
against dust with a porous cover.
ECA10820
NOTICE
●
EWA10942
WARNING
7
Contaminants on the brakes or tires
can cause loss of control.
● 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.
● Before operating the scooter
test its braking performance
and cornering behavior.
TIP
●
●
Consult a Yamaha dealer for advice on what products to use.
Washing, rainy weather or humid
climates can cause the headlight
lens to fog. Turning the headlight
on for a short period of time will
help remove the moisture from the
lens.
7-3
●
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.
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. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
U4P7E2E0.book Page 4 Thursday, August 20, 2009 9:44 AM
SCOOTER CARE AND STORAGE
3. 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 then 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, and then
install the spark plug and the
spark plug cap. WARNING! To
prevent damage or injury
from sparking, make sure to
ground the spark plug electrodes while turning the engine over. [EWA10951]
4. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the sidestand/centerstand.
5. Check and, if necessary, correct
the tire air pressure, and then lift
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.
6. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
7. 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 (30 °F) or more than 30
°C (90 °F)]. For more information
on storing the battery, see page
6-23.
TIP
Make any necessary repairs before
storing the scooter.
7-4
7
U4P7E2E0.book Page 1 Thursday, August 20, 2009 9:44 AM
SPECIFICATIONS
Dimensions:
Overall length:
1860 mm (73.2 in)
Overall width:
670 mm (26.4 in)
Overall height:
1045 mm (41.1 in)
Seat height:
730 mm (28.7 in)
Wheelbase:
1250 mm (49.2 in)
Ground clearance:
95 mm (3.74 in)
Minimum turning radius:
1900 mm (74.8 in)
Engine oil:
-20 -10
Engine:
8
Engine type:
Air cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
125 cm³
Bore × stroke:
51.5 × 60.0 mm (2.03 × 2.36 in)
Compression ratio:
9.50 :1
Starting system:
Electric starter
Lubrication system:
Wet sump
0
10 20 30 40 50 ˚C
SAE 10W-30
SAE 10W-40
SAE 10W-50
SAE 15W-40
SAE 20W-40
Weight:
With oil and fuel:
110.0 kg (243 lb)
Fuel:
Recommended brand:
YAMALUBE
Type:
SAE 10W-30, 10W-40, 10W-50, 15W-40,
20W-40 or 20W-50
SAE 20W-50
Recommended engine oil grade:
API service SG type or higher, JASO
standard MA
Engine oil quantity:
Periodic oil change:
1.00 L (1.06 US qt, 0.88 Imp.qt)
Final transmission oil:
Type:
SAE 85W-140(GL5)
Quantity:
0.13 L (0.14 US qt, 0.11 Imp.qt)
Air filter:
Air filter element:
Oil-coated paper element
8-1
Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
5.5 L (1.45 US gal, 1.21 Imp.gal)
Fuel injection:
Throttle body:
ID mark:
4P72 00
Spark plug (s):
Manufacturer/model:
NGK/CR7E
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Clutch:
Clutch type:
Dry, centrifugal automatic
Transmission:
Primary reduction system:
Helical gear
Primary reduction ratio:
40/15 (2.667)
Secondary reduction system:
Spur gear
Secondary reduction ratio:
38/13 (2.923)
Transmission type:
V-belt automatic
Operation:
Centrifugal automatic type
Chassis:
Frame type:
Steel tube backbone
U4P7E2E0.book Page 2 Thursday, August 20, 2009 9:44 AM
SPECIFICATIONS
Caster angle:
27.00 °
Trail:
75.0 mm (2.95 in)
Front tire:
Type:
Tubeless
Size:
100/90-10 56J
Manufacturer/model:
CHENG SHIN/C-922
Rear tire:
Type:
Tubeless
Size:
100/90-10 56J
Manufacturer/model:
CHENG SHIN/C-940
Loading:
Maximum load:
167 kg (368 lb)
(Total weight of rider, passenger, cargo and
accessories)
Tire air pressure (measured on cold
tires):
Loading condition:
0–83 kg (0–183 lb)
Front:
175 kPa (1.75 kgf/cm², 25 psi)
Rear:
200 kPa (2.00 kgf/cm², 29 psi)
Loading condition:
83–167 kg (183–368 lb)
Front:
175 kPa (1.75 kgf/cm², 25 psi)
Rear:
250 kPa (2.50 kgf/cm², 36 psi)
Front wheel:
Wheel type:
Cast wheel
Rim size:
J10 x 2.15
Rear suspension:
Type:
Unit swing
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
65.0 mm (2.56 in)
Electrical system:
Ignition system:
TCI (digital)
Charging system:
AC magneto
Rear wheel:
Wheel type:
Cast wheel
Rim size:
J10 x MT2.50
Battery:
Front brake:
Type:
Single disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 3 or 4
Rear brake:
Type:
Drum brake
Operation:
Left hand operation
Front suspension:
Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
80.0 mm (3.15 in)
8-2
Model:
GTX7A-BS/YTX7A-BS
Voltage, capacity:
12 V, 6.0 Ah
Headlight:
Bulb type:
Halogen bulb
Bulb voltage, wattage × quantity:
Headlight:
12 V, 35 W/35 W × 1
Tail/brake light:
12 V, 5.0 W/21.0 W × 1
Front turn signal light:
12 V, 10.0 W × 2
Rear turn signal light:
12 V, 16.0 W × 2
Meter lighting:
12 V, 3.4 W × 2
High beam indicator light:
12 V, 1.7 W × 1
8
U4P7E2E0.book Page 3 Thursday, August 20, 2009 9:44 AM
SPECIFICATIONS
Turn signal indicator light:
12 V, 1.7 W × 1
Engine trouble warning light:
12 V, 1.7 W × 1
Fuses:
Main fuse:
15.0 A
8
8-3
U4P7E2E0.book Page 1 Thursday, August 20, 2009 9:44 AM
CONSUMER INFORMATION
EAU48610
Identification numbers
EAU26410
Vehicle identification number
Record the vehicle identification number and model label information in the
spaces provided below for assistance
when ordering spare parts from a
Yamaha dealer or for reference in case
the vehicle is stolen.
VEHICLE IDENTIFICATION
NUMBER:
MODEL LABEL INFORMATION:
1
EAU26500
Model label
1
1. Vehicle identification number
1. Model label
The vehicle identification number is
stamped into the frame.
The model label is affixed to the inside
of the rear storage compartment. (See
page 3-10.) Record the information on
this label in the space provided. This information will be needed when ordering
spare parts from a Yamaha dealer.
TIP
The vehicle identification number is
used to identify your vehicle and may
be used to register it with the licensing
authority in your area.
9
9-1
U4P7E2E0.book Page 1 Thursday, August 20, 2009 9:44 AM
INDEX
A
Acceleration and deceleration................. 5-2
Air filter and V-belt case air filter
elements ............................................. 6-12
Anti-theft alarm (optional)........................ 3-4
Auxiliary light bulb, replacing ................ 6-27
Fuel......................................................... 3-7
Fuel consumption, tips for reducing........ 5-3
Fuel gauge.............................................. 3-4
Fuel tank cap .......................................... 3-6
Fuse, replacing ..................................... 6-25
Handlebar switches ................................ 3-5
Headlight bulb, replacing ...................... 6-25
Helmet holders ....................................... 3-9
High beam indicator light ........................ 3-2
Horn switch............................................. 3-5
I
Identification numbers ............................ 9-1
Ignition circuit cut-off system ................ 3-12
Indicator, indicator lights and
warning light ......................................... 3-2
C
Cables, checking and lubricating .......... 6-20
Care ........................................................ 7-1
Carrier ................................................... 3-11
Catalytic converters ................................ 3-8
Centerstand and sidestand,
checking and lubricating ..................... 6-21
Cowlings and panels,
removing and installing......................... 6-6
D
Dimmer switch ........................................ 3-5
E
Engine break-in....................................... 5-4
Engine oil ................................................ 6-9
Engine trouble warning light.................... 3-3
F
Final transmission oil ............................ 6-11
Front brake lever free play, checking.... 6-17
Front fork, checking .............................. 6-22
Safe-riding points .................................... 1-5
Safety information ...................................1-1
Seat......................................................... 3-8
Self-diagnosis device .............................. 3-4
Sidestand ..............................................3-11
Spark plug, checking...............................6-8
Specifications .......................................... 8-1
Speedometer unit.................................... 3-3
Starting off............................................... 5-2
Starting the engine .................................. 5-1
Start switch..............................................3-5
Steering, checking.................................6-23
Storage....................................................7-3
Storage compartments.......................... 3-10
H
B
Battery................................................... 6-23
Brake fluid, changing ............................ 6-20
Brake fluid level, checking .................... 6-19
Brake lever, front..................................... 3-5
Brake lever, rear ..................................... 3-6
Brake levers, lubricating........................ 6-21
Brake pads and shoes, checking .......... 6-18
Braking.................................................... 5-3
S
K
Keyhole cover......................................... 3-2
L
Luggage hook....................................... 3-11
M
Main switch/steering lock........................ 3-1
Maintenance and lubrication, periodic .... 6-3
Maintenance, emission control system... 6-2
Matte color, caution ................................ 7-1
Model label ............................................. 9-1
P
Parking ................................................... 5-4
Part locations.......................................... 2-1
R
Rear brake lever free play, adjusting.... 6-17
Rear turn signal light and tail/brake
light..................................................... 6-27
T
Throttle cable free play, checking ......... 6-14
Throttle grip and cable,
checking and lubricating ..................... 6-20
Tires ......................................................6-15
Troubleshooting .................................... 6-28
Troubleshooting chart ...........................6-29
Turn signal indicator light ........................ 3-2
Turn signal light bulb (front),
replacing ............................................. 6-26
Turn signal switch ...................................3-5
V
Valve clearance..................................... 6-15
Vehicle identification number .................. 9-1
W
Wheel bearings, checking ..................... 6-23
Wheels ..................................................6-17
U4P7E2E0.book Page 2 Thursday, August 20, 2009 9:44 AM
YAMAHA MOTOR CO., LTD.
PRINTED IN CHINA
2009.08-0.3×2 CR
(E)
DIC183
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