Yamaha | why YH50 | Owner`s manual | Yamaha why YH50 Owner`s manual

OWNER’S MANUAL
YH50
5XS-F8199-E0
EAU04576
INTRODUCTION
Welcome to the Yamaha world of motorcycling!
As the owner of the YH50, 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 YH50. 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!
EAU00005
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the
scooter operator, a bystander, or a person inspecting or repairing the scooter.
A CAUTION indicates special precautions that must be taken to avoid damage to
the scooter.
NOTE :
A NOTE provides key information to make procedures easier or clearer.
NOTE :
This manual should be considered a permanent part of this scooter and should remain with it even if the
scooter is subsequently sold.
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual
contains the most current product information available at the time of printing, there may be minor
discrepancies between your scooter and this manual. If you have any questions concerning this manual,
please consult your Yamaha dealer.
•
•
IMPORTANT MANUAL INFORMATION
EW000002
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS
SCOOTER.
EAUM0023
YH50
OWNER'S MANUAL
© 2003 by MBK INDUSTRIE
1st Edition, January 2003
All rights reserved
Any reprinting or unauthorized use
without the written permission of
MBK INDUSTRIE
is expressly prohibited.
Printed in France.
EAU00009
TABLE OF CONTENTS
1
GIVE SAFETY THE RIGHT OF WAY
1
2
DESCRIPTION
2
3
INSTRUMENT AND CONTROL FUNCTIONS
3
4
PRE-OPERATION CHECKS
4
5
OPERATION AND IMPORTANT RIDING POINTS
5
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6
7
SCOOTER CARE AND STORAGE
7
8
SPECIFICATIONS
8
9
CONSUMER INFORMATION
9
EAU00021
EW000015
GIVE SAFETY THE RIGHT OF WAY
GIVE SAFETY THE RIGHT OF WAY .................................................. 1-1
Further safe-riding points .................................................................... 1-2
1
GIVE SAFETY THE RIGHT OF WAY
Scooters are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However,
they also impose certain limits, which you must accept; even the best scooter does not ignore the laws of
physics.
1
Regular care and maintenance are essential for preserving value and operating condition of your scooter.
Moreover, what is true for the scooter is also true for the rider: good performance depends on being in good
shape. Riding under the influence of medication, drugs and alcohol is, of course, out of the question. Scooter
riders—more than car drivers—must always be at their mental and physical best. Under the influence of
even small amounts of alcohol, there is a tendency to take dangerous risks.
Protective clothing is as essential for the scooter rider as seat belts are for car drivers and passengers.
Always wear a complete scooter suit (whether made of leather or tear-resistant synthetic materials with
protectors), sturdy boots, scooter gloves and a properly fitting helmet. Optimum protective wear, however,
should not encourage carelessness. Although full-coverage helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable. Riders who lack critical selfcontrol run the risk of going too fast and are apt to take chances. This is even more dangerous in wet weather.
The good motorcyclist rides safely, predictably and defensively — avoiding all dangers, including those
caused by others.
Enjoy your ride!
1-1
GIVE SAFETY THE RIGHT OF WAY
EAU02964
Further safe-riding points
•
•
•
•
•
•
•
•
Be sure to signal clearly when making turns.
Braking can be extremely difficult on a wet road. Avoid hard braking, because the scooter 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 lining 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.
Do not carry too much luggage on the scooter. An overloaded scooter is unstable. Use a strong cord to
secure any luggage to the carrier. A loose load will affect the stability of the scooter and could divert
your attention from the road.
1-2
1
EAU01161
DESCRIPTION
Left view .............................................................................................. 2-1
Right view............................................................................................ 2-2
2
DESCRIPTION
Left view
1
2
3
4
2
7
6
5
1.
2.
3.
4.
Rear brake lever
Fuel gauge
Speedometer
Main switch
(page 3-5, 6-12, 6-15)
(page 3-3)
(page 3-3)
(page 3-1, 3-8)
2-1
5. Final transmission oil filler cap (page 6-6)
6. Kick starter
(page 3-7)
7. Air filter
(page 6-7)
DESCRIPTION
Right view
8
9
10
11
2
14
13
12
8.
9.
10.
11.
Rear carrier
Passenger seat
Throttle grip
Front brake lever
12. Luggage hook
(page 3-9)
13. Battery / fuse
—
14. Fuel and oil tank cap
(page 6-9, 6-15)
(page 3-5, 6-12, 6-15)
2-2
(page 3-9)
(page 6-18 — 6-19)
(page 3-5)
EAU00027
INSTRUMENT AND CONTROL FUNCTIONS
Main switch / steering lock .................................................................. 3-1
Indicator and warning lights ................................................................ 3-2
Speedometer unit ................................................................................ 3-3
Fuel gauge .......................................................................................... 3-3
Handlebar switches ............................................................................. 3-4
Front brake lever ................................................................................. 3-5
Rear brake lever .................................................................................. 3-5
Fuel and 2-stroke engine oil tank caps ............................................... 3-5
Fuel ..................................................................................................... 3-6
Catalytic converter .............................................................................. 3-7
2-stroke engine oil ............................................................................... 3-7
Kickstarter ........................................................................................... 3-7
Rider seat ............................................................................................ 3-8
Storage compartment ......................................................................... 3-8
Carrier ................................................................................................. 3-9
Luggage hook ..................................................................................... 3-9
3
INSTRUMENT AND CONTROL FUNCTIONS
EAU00038
O
PE
N
OFF “ ”
All electrical systems are off. The key
can be removed.
PUSH
EAU04470
3
ZAUM0253
EAU00029
CHECK “ ”
The 2-stroke engine oil level warning
light should come on. See page 3-2 for
an explanation of the engine oil level
warning light.
Main switch/steering lock
The main switch/steering lock controls
the ignition and lighting systems, and
is used to lock the steering. The various
positions are described below.
EAU00040
LOCK “ ”
The steering is locked, and all electrical
systems are off. The key can be
removed.
EAU04384
ON “ ”
All electrical circuits are supplied with
power, the taillight and meter lighting
come on, and the engine can be
started. The key cannot be removed.
NOTE :
The headlight comes on as soon as the
engine is started.
To lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “
”
position, and then turn it to “
”
while still pushing it.
3. Remove the key.
To unlock the steering
Push the key in, and then turn it to “
while still pushing it.
3-1
”
EW000016
Never turn the key to “
” or “ ”
while the scooter is moving, otherwise
the electrical systems will be switched
off, which may result in loss of control
or an accident. Make sure that the scooter is stopped before turning the key
to “
” or “ ”.
INSTRUMENT AND CONTROL FUNCTIONS
NOTE :
If the warning light does not come on
when the key is in the " " position or
does not go off after the 2-stroke engine
oil tank has been refilled, have a
Yamaha dealer check the electrical circuit.
1
2
1
ZAUM0184
3
ZAUM0357
EC000000
1. Turn signal indicator light "
"
2. High beam indicator light "
`"
1. Oil level indicator light "
EAU03034
Indicator and warning lights
EAU00057
Turn signal indicator light "
"
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
EAU00063
High beam indicator light " "
This indicator light comes on when the
high beam of the headlight is switched
on.
"
EAU02958
Oil level warning light "
"
This warning light comes on when the
key is in the " " position or when the
oil level in the 2-stroke engine oil tank
is low during operation. If the warning
light comes on during operation, stop
immediately and fill the oil tank with
Yamalube 2 or equivalent 2-stroke
engine oil of either JASO grade "FC"
or ISO grades "EG-C" or "EG-D". The
warning light should go off after the 2stroke engine oil tank has been refilled.
3-2
Do not operate the scooter until you
know that the engine oil level is
sufficient.
INSTRUMENT AND CONTROL FUNCTIONS
2
1
3
1
ZAUM0185
ZAUM0358
1. Speedometer
2. Odometer
1. Fuel gauge
EAU00098
EAU00113
Speedometer unit
Fuel gauge
The speedometer unit is equipped with
a speedometer and an odometer. The
speedometer shows riding speed. The
odometer shows the total distance
traveled.
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 "E", refuel as soon as possible.
NOTE :
Do not allow the fuel tank to empty itself
completely.
3-3
INSTRUMENT AND CONTROL FUNCTIONS
EAUM0097
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 turn off the turn signal lights, push the cancel button, and
then release it.
1
2
3
4
ZAUM0359
1.
2.
3.
4.
Dimmer switch " /
Cancel button
Turn signal switch "
Horn switch "
"
EAU00129
"
/
Horn switch "
"
Press this switch to sound the horn.
"
EAU00118
1
3
ZAUM0360
1. Start switch "
"
EAUM0063
Handlebar switches
Start switch " "
Push this switch while applying the front
or rear brake to crank the engine with
the starter.
EAU03888
Dimmer switch " / "
Set this switch to " " for the high beam
and to " " for the low beam.
EC000005
See page 5-1 for starting instructions prior to starting the engine.
3-4
INSTRUMENT AND CONTROL FUNCTIONS
1
1
3
2
1
ZAUM0084
ZAUM0361
ZAUM0085
1. Front brake lever
1. Rear brake lever
1. Oil tank cap
2. Fuel tank cap
EAU03882
EAU00163
Front brake lever
Rear 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.
The rear brake lever is located on the
left handlebar grip. To apply the rear
brake, pull this lever toward the
handlebar grip.
EAU03463
Fuel and 2-stroke engine oil
tank caps
The fuel tank cap and the 2-stroke
engine oil tank cap are located under
the seat. (See page 3-8 for seat opening
and closing procedures.)
Fuel tank cap
To remove the fuel tank cap, turn it
counterclockwise, and then pull it off.
To install the fuel tank cap, turn it
clockwise.
3-5
INSTRUMENT AND CONTROL FUNCTIONS
EAU00185
EC000008
1
Immediately wipe off spilled fuel with
a clean, dry, soft cloth, since fuel may
deteriorate painted surfaces or plastic parts.
2
ZAUM0204
ZAUM0020
EAU04206
1. Filler tube
2. Fuel level
2-stroke engine oil tank cap
To remove the 2-stroke engine oil tank
cap, pull it off.
To install the 2-stroke engine oil tank
cap, push it into the oil tank opening.
EAU03753
Fuel
Make sure that there is sufficient fuel
in the tank. Fill the fuel tank to the
bottom of the filler tube as shown.
EW000130
EW000025
Make sure that the fuel and 2-stroke
engine oil tank caps are properly
installed before riding the scooter.
•
•
Do not overfill the fuel tank,
otherwise it may overflow when
the fuel warms up and expands.
Avoid spilling fuel on the hot
engine.
3-6
Recommended fuel:
REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity:
Total amount:
7.2 L
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.
3
INSTRUMENT AND CONTROL FUNCTIONS
EAU03098
2-stroke engine oil
This scooter is equipped with a catalytic
converter in the muffler.
Make sure that there is sufficient oil in
the 2-stroke engine oil tank. Add the
recommended 2-stroke engine oil if
necessary.
EW000128
3
EAU03750
Catalytic converter
The exhaust system is hot after
operation. Make sure that the
exhaust system has cooled down
before doing any maintenance work.
NOTE :
Make sure that the 2-stroke engine oil
tank cap is properly installed.
1
ZAUM0362
1. Kickstarter
EC000114
The following precautions must be
observed to prevent a fire hazard or
other damages.
Use only unleaded gasoline.
The use of leaded gasoline will
cause unrepairable damage to
the catalytic converter.
Never park the scooter near
possible fire hazards such as
grass or other materials that
easily burn.
Do not allow the engine to idle
too long.
•
EAUS0015
Recommended oil:
Yamalube 2 or equivalent
2-stroke engine oil
(JASO grade "FC",
or ISO grades "EG-C" or "EG-D")
Oil quantity:
1.3 L
•
•
3-7
Kickstarter
To start the engine, push the kickstarter
down lightly with your foot until the
gears engage, and then push it down
smoothly but forcefully.
O
PE
N
OPEN
INSTRUMENT AND CONTROL FUNCTIONS
LOCK
OPEN
UNLOCK
PUSH
OPEN
LOCK
OPEN
UNLOCK
N
OPE
LOCK
OPEN
UNLOCK
ZAUM0363
ZAUM0253
ZAUM0364
EAU03091
EAUM0096
Rider seat
To open the rider seat
1. Place the scooter on the
centerstand.
2. Insert the key into the main switch,
and then turn it counterclockwise.
NOTE :
Do not push inward when turning the
key.
Storage compartment
To close the rider seat
1. Fold the rider 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.
NOTE :
Make sure that the seat is properly
secured before riding.
3. Fold the rider seat up.
To unlock the storage compartment
Insert the key in the lock and turn it 1/4
turn clockwise.
To open the storage compartment
when it is unlocked
Turn the knob 1/4 turn clockwise. The
knob will return to its original position
after released.
To close the storage compartment
Push the lid into the original position
To lock the storage compartment
Insert the key in the lock and turn it 1/4
turn counterclockwise, and then
remove the key.
3-8
3
INSTRUMENT AND CONTROL FUNCTIONS
EWA00005
1
•
•
3
1
Do not exceed the load limit of 1.5
kg for the storage compartment.
Do not exceed the maximum
load of 182 kg for the vehicle.
ZAUM0365
ZAUM0366
1. Carrier
1. Luggage hook
EAU00320
Carrier
EAUT0020
Luggage hook
EW000032
•
•
Do not exceed the load limit of
3.0 kg for the carrier.
Do not exceed the maximum
load of 182 kg for the vehicle.
3-9
EWAT0002
•
•
Do not exceed the load limit of
3.0 kg for the luggage hook.
Do not exceed the maximum
load of 182 kg for the vehicle.
EAU01114
PRE-OPERATION CHECKS
Pre-operation check list ....................................................................... 4-1
4
PRE-OPERATION CHECKS
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or
loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual
inspection, to check the following points before each ride.
EAU03439
Pre-operation check list
ITEM
CHECKS
PAGE
Fuel
• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
3-5 — 3-6
2-stroke engine oil
• Check oil level in oil tank.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.
3-5 — 3-7
Final transmission oil
• Check vehicle for oil leakage.
Front brake
•
•
•
•
•
Rear brake
• Check operation.
• Check pedal free play.
• Adjust if necessary.
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.
4
6-6
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
3-5, 6-13 — 6-15
3-5, 6-13 — 6-15
4-1
6-9, 6-15
PRE-OPERATION CHECKS
ITEM
CHECKS
Wheels and tires
•
•
•
•
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
Brake levers
• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
Centerstand
• Make sure that operation is smooth.
• Lubricate pivot if necessary.
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.
Instruments, lights, signals
and switch
• Check operation.
• Correct if necessary.
Battery
• Check fluid level.
• Fill with distilled water if necessary.
PAGE
6-10 — 6-11
6-12, 6-15
6-16
—
4
3-2 — 3-4
6-18
NOTE :
Pre-operation checks should be made each time the scooter is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved.
EWA00033
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the scooter.
4-2
EAU00372
OPERATION AND IMPORTANT RIDING POINTS
Starting the engine .............................................................................. 5-1
Starting off........................................................................................... 5-2
Acceleration and deceleration ............................................................. 5-2
Braking ................................................................................................ 5-3
Tips for reducing fuel consumption ..................................................... 5-3
Engine break-in ................................................................................... 5-4
Parking ................................................................................................ 5-4
5
OPERATION AND IMPORTANT RIDING POINTS
•
•
5
•
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or
function that you do not
thoroughly understand.
Never start the engine or
operate it in a closed area for
any length of time. Exhaust fumes are poisonous, and
inhaling them can cause loss of
consciousness and death
within a short time. Always
make sure that there is
adequate ventilation.
For safety, always start the
engine with the centerstand
down.
O
PE
N
EAU01118
EW000129
PUSH
ZAUM0367
ZAUM0253
EAU02960
Starting the engine
EC000046
See page 5-4 for engine break-in instructions prior to operating the
vehicle for the first time.
1. Turn the key to " ", and when the
oil level warning light comes on,
turn it to " ".
EC000045
If the oil level warning light does not
come on, have a Yamaha dealer
check the electrical circuit.
2. Close the throttle completely.
5-1
3. While applying the front or rear
brake, start the engine by pushing
the start switch or by pushing the
kickstarter lever down.
NOTE :
If the engine fails to start by pushing
the start switch, release the 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. If the engine does
not start with the starter motor, try using
the kickstarter.
OPERATION AND IMPORTANT RIDING POINTS
ECA00045
For maximum engine life, never
accelerate hard when the engine is
cold!
ZAUM0268
ZAUM0368
EAU04473
Starting off
NOTE :
Before starting off, allow the engine to
warm up.
1. While pulling the rear brake lever
with your left hand and holding the
carrier with your right hand, push
the scooter off the centerstand.
2. Sit astride the seat, and then
adjust the rear view mirrors.
3. Switch the turn signal on.
4. Check for oncoming traffic, and
then slowly turn the throttle grip
(on the right) in order to take off.
5. Switch the turn signal off.
5-2
EAU00434
Acceleration and
deceleration
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
OPERATION AND IMPORTANT RIDING POINTS
•
ZAUM0269
EAU00435
Braking
5
1. Close the throttle completely.
2. Apply both front and rear brakes
simultaneously while gradually
increasing the pressure.
•
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.
EW000057
•
Avoid braking hard or suddenly
(especially when leaning over
to one side), otherwise the
scooter may skid or overturn.
5-3
EAU03093
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:
Thoroughly warm up the engine.
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).
•
•
•
OPERATION AND IMPORTANT RIDING POINTS
EAU00436
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1,000 km. 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
1,000 km. The various parts in the
engine wear and polish themselves to
the correct operating clearances.
During this period, prolonged fullthrottle operation or any condition that
might result in engine overheating must
be avoided.
150 — 500 km
Avoid prolonged operation above 1/2
throttle.
500 — 1,000 km
Avoid cruising speeds in excess of 3/
4 throttle.
EAU00461
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EW000058
•
ECAT0001
After 1,000 km of operation, be sure
to replace the final transmission oil.
1,000 km and beyond
Avoid prolonged full throttle operation.
Vary speeds occasionally.
•
Since the engine and exhaust
system can become very hot,
park in a place where
pedestrians or children are not
likely to touch them.
Do not park on a slope or on
soft ground, otherwise the
scooter may overturn.
EC000062
EAUT0003*
0 — 150 km
Avoid operation above 1/3 throttle. Stop
the engine and let it cool for 5 to 10
minutes after every hour of operation.
Vary the speed of the scooter from time
to time. Do not operate it at one set
throttle position.
EC000049
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
5-4
Never park in an area where there
are fire hazards such as grass or
other flammable materials.
5
EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR
Periodic maintenance and lubrication chart ............ 6-2
Removing and installing the panel .......................... 6-5
Panel A .................................................................... 6-5
Checking the spark plug ......................................... 6-5
Final transmission oil .............................................. 6-6
Cleaning the air filter element ................................. 6-7
Adjusting the carburetor .......................................... 6-9
Adjusting the throttle cable free play ....................... 6-9
Tires ...................................................................... 6-10
Cast wheels .......................................................... 6-11
Adjusting the front brake lever free play ................ 6-12
Adjusting the front brake lever free play ................ 6-12
Checking the front brake pads .............................. 6-13
and rear brake shoes
Checking the brake fluid level ............................... 6-14
Changing the brake fluid ....................................... 6-15
Checking and lubricating the throttle grip .............. 6-15
and cable
Lubricating the front and rear brakes levers .......... 6-15
Checking and lubricating the centerstand ............. 6-16
Checking the front fork .......................................... 6-16
Checking the steering ........................................... 6-17
Checking the wheel bearings ................................ 6-17
Battery ................................................................... 6-18
Replacing the fuse ................................................ 6-19
Replacing a headlight bulb .................................... 6-20
Replacing the brake taillight bulb .......................... 6-21
Replacing a turn signal light bulb .......................... 6-21
Troubleshooting ..................................................... 6-22
Troubleshooting chart ............................................ 6-23
6
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03453
Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in the
safest and most efficient condition possible. The most important points of
scooter inspection, adjustment, and
lubrication are explained on the
following pages.
EW000060
EAU00466
EW000061
This scooter is designed for use on
paved roads only. If this scooter is
operated in abnormally dusty,
muddy or wet conditions, the air filter
element should be cleaned or
replaced more frequently, otherwise
rapid engine wear may result.
Consult a Yamaha dealer for proper
maintenance intervals.
If you are not familiar with scooter
maintenance work, have a Yamaha
dealer do it for you.
6
6-1
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03686
Periodic maintenance and lubrication chart
NOTE :
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
From 30,000 km, repeat the maintenance intervals starting from 6,000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
•
•
•
ODOMETER READING (x 1,000 km)
NO.
CHECK OR MAINTENANCE JOB
ITEM
1
6
12
18
24
ANNUAL
CHECK
Fuel line
• Check fuel hoses and vacuum hose for cracks or damage.
√
√
√
√
√
2
Spark plug
• Replace.
√
√
√
√
√
3
Air filter element
• Clean.
√
1
*
4
*
Battery
5
*
Front brake
• Check electrolyte level and specific gravity.
• Make sure that the breather hose is properly routed.
• Check operation, fluid level and vehicle for fluid leak
(See NOTE on page 6-4.)
√
• Replace brake pads.
6
7
*
*
Rear brake
Brake hose
√
√
• Replace.
√
√
√
√
√
√
√
√
√
√
Whenever worn to the limit
• Check operation and adjust brake lever free play.
√
√
√
*
Wheels
√
√
• Replace brake shoes.
Whenever worn to the limit
• Check for cracks or damage.
√
√
• Replace. (See NOTE on page 6-4.)
8
6
√
√
• Check runout and for damage.
6-2
√
√
Every 4 years
√
√
√
√
√
PERIODIC MAINTENANCE AND MINOR REPAIR
ODOMETER READING (x 1,000 km)
NO.
CHECK OR MAINTENANCE JOB
ITEM
Tires
•
•
•
•
10 *
Wheel bearings
• Check bearing for looseness or damage.
11 *
Steering bearings
9
*
1
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
• Check bearing play and steering for roughness.
√
6
12
18
24
ANNUAL
CHECK
√
√
√
√
√
√
√
√
√
√
√
√
√
• Lubricate with lithium-soap-based grease.
6
Every 24,000 km
12 *
Chassis fasteners
• Make sure that all nuts, bolts and screws are
properly tightened.
√
√
√
√
√
13
Centerstand
• Check operation.
• Lubricate.
√
√
√
√
√
14 *
Front fork
• Check operation and for oil leakage.
√
√
√
√
15 *
Shock absorber assembly • Check operation and shock absorber for oil leakage.
√
√
√
√
16 *
Carburetor
• Adjust engine idling speed.
√
√
√
√
√
√
17 *
Autolube pump
• Check operation.
• Bleed if necessary.
√
√
√
18
Final transmission oil
• Check vehicle for oil leakage.
√
• Change.
√
19 *
V-belt
20 *
Front and rear brake
switches
√
√
√
√
• Replace.
√
Every 10,000 km
√
• Check operation.
6-3
√
√
√
√
√
PERIODIC MAINTENANCE AND MINOR REPAIR
ODOMETER READING (x 1,000 km)
NO.
CHECK OR MAINTENANCE JOB
ITEM
21
Moving parts and cables
• Lubricate.
22 *
Lights, signals and
switches
• Check operation.
• Adjust headlight beam.
1
√
6
12
18
24
ANNUAL
CHECK
√
√
√
√
√
√
√
√
√
√
EAU03541*
NOTE :
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 change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
•
•
6
6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01651
Checking the spark plug
1
ZAUM0369
ZAUM0370
1. Panel A
EAU01777
Removing and installing the
panel
6
The panel shown above needs to be
removed to perform some of the maintenance jobs described in this chapter.
Refer to this section each time the panel needs to be removed and installed.
EAUM0095
Panel A
To remove the panel
1. Open the seat. (See page 3-8 for
seat opening and closing
procedures.)
2. Remove the panel by pulling it up
as shown.
To install the panel
1. Insert the rear of the panel in the
original position, and then push
the front of the panel inward..
2. Close the seat.
6-5
The spark plug is an important engine
component, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
it 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.
The porcelain insulator around the
center electrode of the spark plug
should be a medium-to-light tan (the
ideal color when the scooter is ridden
normally). If the spark plug shows a
distinctly different color, the engine
could be defective. Do not attempt to
diagnose such problems yourself.
Instead, have a Yamaha dealer check
the scooter.
PERIODIC MAINTENANCE AND MINOR REPAIR
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
a
Tightening torque:
Spark plug:
23 Nm (2.3 m•kg)
ZAUM0037
a Spark plug gap
If the spark plug shows signs of
electrode erosion and excessive
carbon or other deposits, it should be
replaced.
Specified spark plug:
BR8HS (NGK)
NOTE :
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4 — 1/2 turn
past finger tight. However, the spark
plug should be tightened to the
specified torque as soon as possible.
Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Spark plug gap:
0.6 — 0.7 mm
6-6
EAU04228
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 it up 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.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
1
Recommended final transmission oil:
See page 8-1.
Oil quantity:
0.11 L
2
ZAUM0371
EWA00062
•
1. Oil filler cap
2. Oil drain bolt
6
4. Remove the oil filler cap and drain
bolt to drain the oil from the final
transmission case.
5. Install the final transmission oil
drain bolt, and then tighten it to
the specified torque.
•
Make sure that no foreign
material enters the final transmission case.
Make sure that no oil gets on
the tire or wheel.
7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
Tightening torque:
Final transmission oil drain bolt:
17 Nm (1.7 m•kg)
6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten the
oil filler cap.
6-7
1
ZAUM0372
1. Screws
EAUM0071
Cleaning the air filter element
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more
frequently if you are riding in unusually
wet or dusty areas.
1. Remove the air filter case cover
by removing the screws.
PERIODIC MAINTENANCE AND MINOR REPAIR
EC000082
1
2
•
1
3
ZAUM0373
4
ZAUM0156
1. Air filter element
2. Pull the air filter element out, clean
it with solvent, and then squeeze
the remaining solvent out.
EW000075
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.
EC000089
To avoid damaging the foam material,
handle it gently and carefully, and do
not twist or wring it.
3. Apply oil of the recommended
type to the entire surface of the
element, and then squeeze the
excess oil out.
NOTE :
The air filter element should be wet but
not dripping
Recommended oil:
Engine oil
4. Insert the element into the air filter
case.
6-8
•
Make sure that the air filter
element is properly seated in
the air filter case.
The engine should never be
operated without the air filter
element installed, otherwise the
piston(s) and/or cylinder(s)
may become excessively worn.
5. Install the air filter case cover by
installing the screws.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00631
Adjusting the carburetor
The carburetor is an important part of
the engine and requires very
sophisticated adjustment. Therefore, all
carburetor adjustments should be left
to a Yamaha dealer, who has the
necessary professional knowledge and
experience.
a
ZAUM0051
a Throttle cable free play
EAU00635
Adjusting the throttle cable
free play
6
The throttle cable free play should
measure 1.5 — 3.0 mm at the throttle
grip. Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
•
•
ZAUM0053
EAU04551
Tires
To maximize the performance,
durability, and safe operation of your
scooter, 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.
EW000082
EW000077
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.
Because loading has an enormous
impact on the handling, braking, performance and safety characteristics of
your scooter, you should keep the
following precautions in mind.
NEVER OVERLOAD THE SCOOTER! Operation of an overloaded
scooter may result in tire damage,
loss of control, or severe injury.
Make sure that the total weight of
rider, cargo, and accessories
does not exceed the specified
maximum load for the vehicle.
Do not carry along loosely
packed items, which can shift
during a ride.
Securely pack the heaviest items
close to the center of the scooter
and distribute the weight evenly
on both sides.
Adjust the suspension and tire air
pressure with regard to the load.
Check the tire condition and air
pressure before each ride.
Tire air pressure
(measured on cold tires)
Load*
•
Front
Rear
Up to 90 kg*
180 kPa
1.8 kgf/cm2
1.8 bar
190 kPa
1.9 kgf/cm2
1.9 bar
90 kg ~
maximum*
180 kPa
1.8 kgf/cm2
1.8 bar
210 kPa
2.1 kgf/cm2
2.1 bar
Maximum load*
182 kg
* Total weight of rider, passenger, cargo and
accessories
6-10
•
•
•
•
6
PERIODIC MAINTENANCE AND MINOR REPAIR
1
Tire information
This scooter is equipped with tubeless
tires.
Front
2
Manufacturer
Size
Type
MICHELIN
2 1/2 -16 42M
M29S TT
Rear
ZAUM0054
Manufacturer
1. Tire tread depth
2. Tire sidewall
6
MICHELIN
Size
Type
2 3/4 -16 46M
M29S TT
Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail
or glass fragments in it, or if the sidewall
is cracked, have a Yamaha dealer replace the tire immediately.
Minimum tire tread depth
(front and rear)
EAU03773
Cast wheels
To maximize the performance,
durability, and safe operation of your
scooter, 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.
•
•
1.6 mm
•
NOTE :
The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
a
a
b
1
a
ZAUM0107
ZAUM0108
ZAUM0374
a Front brake lever free play
a Rear brake lever free play
1. Adjusting nut
EAU00697*
EAU04469
Adjusting the front brake
lever free play
Adjusting the rear brake
lever free play
The brake lever free play should
measure 10—20 mm as shown.
Periodically check the brake lever free
play and, if necessary, have a Yamaha
dealer adjust it.
The brake lever free play should
measure 10—20 mm as shown.
Periodically check the brake lever free
play and, if necessary, adjust it as
follows.
EW000100
An incorrect brake lever free play
indicates a hazardous condition in
the brake system. Do not operate the
scooter until the brake system has
been checked or repaired by a
Yamaha dealer.
6-12
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 .
EW000101
If proper adjustment cannot be
obtained as described, have a
Yamaha
dealer
make
this
adjustment.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00720
Checking the front brake
pads and rear brake shoes
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.
a
1
2
ZAUM0375
ZAUM0376
a Lining thickness
6
1. Wear indicator
2. Wear limit
EAU01436
EAU04502
Front brake pads
Check each front brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 0.5 mm, have a
Yamaha dealer replace the brake pads
as a set.
Rear brake shoes
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.
6-13
PERIODIC MAINTENANCE AND MINOR REPAIR
Observe these precautions:
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.
1
•
•
ZAUM0377
1. Brake fluid level
EAU00732
Checking the brake fluid
level
Insufficient brake fluid may allow air to
enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake
system for leakage.
Recommended brake fluid:
DOT 4
NOTE :
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.
6-14
•
•
•
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.
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.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
EAUM0008
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and
lubrication chart. In addition, have the
brake hose replaced every four years
or whenever it is damaged or leaking.
EAU04034
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addition, the cable should be lubricated or
replaced at the intervals specified in the
periodic maintenance chart.
ZAUM0061
6
EAU00774
EAU03118
Adjusting the Autolube pump
Lubricating the front and rear
brake levers
The Autolube pump is a vital and
sophisticated component of the engine,
which must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
The pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic maintenance and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
6-15
PERIODIC MAINTENANCE AND MINOR REPAIR
ZAUM0062
To check the operation
1. Place the scooter on a level surface and hold it in an upright position.
2. While applying the front brake,
push down hard on the
handlebars several times to check
if the front fork compresses and
rebounds smoothly.
ZAUM0378
EAU04123
Checking and lubricating the
centerstand
The operation of the centerstand should
be checked before each ride, and the
pivots and metal-to-metal contact surfaces should be lubricated if necessary.
EAU02939
Checking the front fork
EC000098
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
EWA00055
EW000115
If the centerstand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
Securely support the scooter so that
there is no danger of it falling over.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Check the inner tubes for scratches,
damage and excessive oil leakage.
6-16
If any damage is found or the front
fork does not operate smoothly, have
a Yamaha dealer check or repair it.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
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.
ZAUM0379
EAU00794
Checking the steering
6
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Place a stand under the engine
to raise the front wheel off the
ground.
EW000115
Securely support the scooter so that
there is no danger of it falling over.
6-17
EAU01144
Checking the wheel bearings
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.
PERIODIC MAINTENANCE AND MINOR REPAIR
EW000116
EAUM0049
Battery
A poorly maintained battery will corrode
and discharge quickly. The electrolyte
level, battery lead connections and
breather hose routing should be
checked before each ride and at the
intervals specified in the periodic maintenance and lubrication chart.
To check the electrolyte level
1. Place the scooter on a level surface and hold it in an upright position.
NOTE :
Make sure that the scooter is positioned
straight up when checking the
electrolyte level.
2. Remove panel A. (See page 6-5
for panel removal and installation
procedures.)
•
1
UPPER
LOWER
+
2
ZAUM0106
1. Maximum level mark
2. Minimum level mark
3. Check the electrolyte level in the
battery.
NOTE :
The electrolyte should be between the
minimum and maximum level marks.
4. If the electrolyte is at or below the
minimum level mark, add distilled
water to raise it to the maximum
level mark.
6-18
•
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.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
•
KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF
CHILDREN.
EC000100
Use only distilled water, as tap water
contains minerals that are harmful
to the battery.
5. Check and, if necessary, tighten
the battery lead connections and
correct the breather hose routing.
6
4. After installation, make sure that
the battery leads are properly
connected to the battery terminals
and that the breather hose is
properly routed, in good condition,
and not obstructed.
1
EC000099
ZAUM0380
If the breather hose is positioned in
such a way that the frame is exposed
to electrolyte or gas expelled from
the battery, the frame could suffer
structural and external damages.
To store the battery
1. If the scooter will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
2. If the battery will be stored for
more than two months, check the
specific gravity of the electrolyte
at least once a month and fully
charge the battery whenever
necessary.
3. Fully charge the battery before
installation.
1. Fuse
EAU00809
Replacing the fuse
The fuse holder is located beside the
battery compartment behind panel A.
(See page 6-5 for panel removal and
installation procedures.)
If the fuse is blown, replace it as follows.
1. Turn the key to " " and turn off
all electrical circuits.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
Specified fuse:
7.5 A
6-19
PERIODIC MAINTENANCE AND MINOR REPAIR
EC000103
EW000119
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.
Headlight bulbs get very hot.
Therefore, keep flammable products
away from a lit headlight bulb, and
do not touch the bulb until it has
cooled down.
3. Turn the key to " " 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.
1
ZAUM0381
1. Headlight bulb holder
EAU00846
Replacing the headlight bulb
If the headlight bulb burns out, replace
it as follows.
1. Remove the headlight unit by
removing the screws.
2. Disconnect the headlight lead
connectors.
3. Remove the headlight bulb holder
by pushing it inward and turning it
counterclockwise, and then
remove the defective bulb.
6-20
4. Place a new bulb into position,
and then secure it with the bulb
holder.
5. Connect the lead connectors, and
then install the headlight unit by
installing the screws.
6. Have a Yamaha dealer adjust the
headlight beam if necessary.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
ZAUM0382
ZAUM0383
EAUM0037
Replacing the brake/taillight
bulb
6
1. Remove the brake/taillight lens by
removing the screws.
2. Remove the brake/taillight bulb
holder by turning it 1/4 turn
counter-clockwise.
3. Remove the defective bulb.
4. Place a new bulb into position,
and then secure it with the bulb
holder.
5. Place the brake/taillight lens in the
original position, and then install
the screw.
EAU03497
Replacing a turn signal light
bulb
1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it
counterclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it
clockwise until it stops.
4. Install the lens by installing the
screw.
ECA00065
Do not overtighten the screw,
otherwise the lens may break.
6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01008
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.
6
6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01397
Troubleshooting chart
EW000125
Keep away open flames and do not smoke while checking or working on the fuel system.
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.
6
3. Ignition
Wet
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Open the throttle halfway and operate
the electric starter.
Dry
Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the battery.
Remove the spark plug
and check the electrodes.
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.
6-23
The engine does not start.
Have a Yamaha dealer
check the vehicle.
EAU03434
SCOOTER CARE AND STORAGE
Care .................................................................................................... 7-1
Storage ............................................................................................... 7-3
7
SCOOTER CARE AND STORAGE
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.
7
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
products onto seals, gaskets and
wheel axles. Always rinse the dirt
and degreaser off with water.
•
Cleaning
ECA00011
•
•
Avoid using strong acidic wheel
cleaners, especially on 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
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.
7-1
•
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.
SCOOTER CARE AND STORAGE
•
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.
NOTE :
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.
ECA00012
Do not use warm water since it
increases the corrosive action of the
salt.
2. Apply a corrosion protection spray
on all metal, including chromeand nickel-plated, surfaces to
prevent corrosion.
7-2
After cleaning
1. Dry the scooter with a chamois or
an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stainlesssteel parts, including the exhaust
system. (Even the thermally
induced discoloring of stainlesssteel exhaust systems can be
removed through polishing.)
3. To prevent corrosion, it is
recommended to apply a corrosion protection spray on all metal,
including chrome- and nickelplated, 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.
7
SCOOTER CARE AND STORAGE
EWA00002
•
•
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.
NOTE :
Consult a Yamaha dealer for advice on
what products to use.
Storage
Short-term
Always store your scooter in a cool, dry
place and, if necessary, protect it
against dust with a porous cover.
ECA00015
•
ECA00013
7
•
•
•
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.
•
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.
7-3
Long-term
Before storing your scooter for several
months:
1. Follow all the instructions in the
"Care" section of this chapter.
2. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
fuel tank.
3. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
4. Perform the following steps to
protect the cylinder, piston rings,
etc. from corrosion.
SCOOTER CARE AND STORAGE
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.
EWA00003
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
5. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
6. 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.
7. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
8. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an
excessively cold or warm place
(less than 0 °C or more than 30
°C). For more information on
storing the battery, see page 618.
7-4
NOTE :
Make any necessary repairs before
storing the scooter.
7
EAU01038
SPECIFICATIONS
Specifications ...................................................................................... 8-1
Conversion table ................................................................................. 8-4
8
SPECIFICATIONS
Specifications
Model
8
YH50
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
1.940 mm
685 mm
1.105 mm
765 mm
1.294 mm
125 mm
1.800 mm
Weight:
Wet (with oil and a full fuel tank)
78 kg
Engine:
Engine type
Cylinder arrangement
Displacement
Bore x stroke
Compression ratio
Starting system type
Lubrication system
Engine oil:
Type
Classification
Capacity
Transmission oil:
Type
Capacity
Périodic oil change
Total amount
0.11L
0.13L
Air filter type:
Wet type element
Fuel:
Recommended fuel
Fuel tank capacity
Air cooled, 2 strokes
Single cylinder, horizontal
49.2 cm3
40.0 x 39.2
7.25:1
Electric and kick starter
Separate lubrication
(Autolube)
Yamalube 2
or 2 strokes engine oil
Jaso FC ou ISO EG-C, EG-D
1.3 L
8-1
SAE 10W30 type SE
Regular unleaded gasoline
(RON 91 mini)
7L
Carburetor:
Type / quantity
Manufacturer
PY-12
GURTNER
Spark plug:
Type / Manufacturer
Spark plug gap
BR8HS / NGK
0.6—0.7 mm
Clutch type:
Dry, centrifugal automatic
Transmission:
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
Helical gear
52/13 (4.000)
Spur gear
45/12 (3.750)
V-belt automatic
Centrifugal automatic type
SPECIFICATIONS
Chassis:
Frame type
Caster angle ((degree))
Trail
Tires:
Front:
Type
Size
Manufacturer / Model
Rear:
Type
Size
Manufacturer / Model
Maximum load *
Air pressure (cold tire):
Up to 90 Kg load*
Front
Rear
90 kg load — maximum
load *
Front
Rear
Wheels:
Front
Type
Size
Rear
Type
Size
Steel tube underbone
25°
101.3 mm
Tubeless
2 1/2-16 42M
MICHELIN / M29S TT
Brakes:
Front
Type
Operation
Type brake fluid
Rear
Type
Operation
Tubeless
2 3/4-16 46M
MICHELIN / M29S TT
182 Kg
180 kpa
190 kpa
Suspension:
Front suspension
Rear suspension
180 kpa
210 kpa
Shock absorber:
Front fork type
Rear shock absorber
assembly type
* Total weight of rider, passenger, cargo and accessories.
Wheel travel:
Front wheel travel
Rear wheel travel
8-2
Cast wheel
16 X MT 1.60
Cast wheel
16 X MT 1.85
Single disc brake
Right hand operation
DOT 4
Single drum brake
Left hand operation
Telescopic fork
Unit swing
Coil spring/oil damper
Coil spring/oil damper
80 mm
70 mm
8
SPECIFICATIONS
Electrical:
Ignition system type
Charging system
Battery
Model
Voltage/capacity
GM4-3B, YB4L-B, FB4L-B
12 V / 4 Ah
Headlight type:
Bulb
C.D.I
Flywheel magneto
Bulbs (voltage/wattage x quantity):
Headlight
12V, 35W/35Wx1
Brake/brake light
12V, 5W/21Wx1
Turn signal light
Front
12V, 10Wx2
Rear
12V, 10Wx2
Meter lights
12V, 1.2Wx2
High beam indicator light
12V, 1.2Wx1
Turn signal indicator light
12V, 1.2Wx1
Oil warning light
12V, 2Wx1
8
Fuses:
Main fuse
7.5 A
8-3
SPECIFICATIONS
EAU04513
Conversion table
Conversion table
METRIC SYSTEM TO IMPERIAL SYSTEM
All specification data in this manual are listed in SI and
METRIC UNITS.
Metric unit
Use this table to convert METRIC unit values to IMPERIAL
unit values.
Example:
METRIC VALUE
2 mm
CONVERSION
FACTOR
0.03937
Torque
ft•lbf
in•lbf
ft•lbf
in•lbf
Weight
kg
g
2.205
0.03527
lb
oz
Speed
km/h
0.6214
mi/h
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
Volume,
Capacity
cc (cm3)
cc (cm3)
L (liter)
L (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cu•in
qt (IMP liq.)
gal (IMP liq.)
Miscellaneous
kg/mm
kgf/cm2
°C
55.997
14.2234
1.8 + 32
lb/in
psi (lbf/in2)
°F
0.08 in
8-4
Imperial unit
7.233
86.794
0.0723
0.8679
IMPERIAL VALUE
=
Conversion factor
m•kgf
m•kgf
cm•kgf
cm•kgf
8
EAU01039
CONSUMER INFORMATION
Identification numbers ......................................................................... 9-1
Key identification number .................................................................... 9-1
Vehicle identification number .............................................................. 9-1
Model label .......................................................................................... 9-2
9
CONSUMER INFORMATION
EAU02944
Identification numbers
Record the key identification number,
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.
1
1
ZAUM0384
ZAUM0070
1. Vehicle identification number
1. Key identification number
1. KEY IDENTIFICATION NUMBER:
EAU01041
2. VEHICLE
NUMBER:
9
IDENTIFICATION
EAU01044
Key identification number
Vehicle identification number
The key identification number is
stamped into the key tag.
Record this number in the space
provided and use it for reference when
ordering a new key.
The vehicle identification number is
stamped into the frame.
3. MODEL LABEL INFORMATION:
9-1
NOTE :
The vehicle identification number is
used to identify your scooter and may
be used to register your scooter with
the licensing authority in your area.
CONSUMER INFORMATION
1
ZAUM0385
1. Model label
EAU01278
Model label
The model label is affixed to the bottom
of the seat. (See page 3-8 for seat
opening procedures.) Record the information on this label in the space
provided. This information will be
needed when ordering spare parts from
a Yamaha dealer.
9
9-2
CONSUMER INFORMATION
EAU01052*
YOU ARE HEREBY REMINDED THAT MODIFICATIONS TO THE ENGINE OR THE POWER OF THE SCOOTER ARE
FORBIDDEN BY LAW.
ANY CHANGES FOR THE PURPOSE OF RAISING THE TOP SPEED OF THE VEHICLE OR BOOSTING THE POWER
OF THE ENGINE WOULD LEAD TO THE SCOOTER BEING
CLASSED AS A SCOOTER.
THIS WOULD REQUIRE THE OWNER:
•
TO OBTAIN A NEW TYPE APPROVAL
•
TO OBTAIN A SCOOTER REGISTRATION LICENSE
•
TO HOLD A DRIVING LICENSE
IN ADDITION, SUCH CHANGES WOULD LEAD TO THE INVALIDATION OF TIE INSURANCE COVER, SINCE
INSURANCE POLICIES EXPLICITLY FORBID TECHNICAL CHANGES WHICH HAVE THE PURPOSE OF BOOSTING
THE PERFORMANCE.
9
FOR THE REASONS SET OUT ABOVE, A BREACH OF THE PROHIBITION TO TAMPER WITH THE ENGINE IS
PUNISHED BY LAW BY APPROPRIATE FINES INCLUDING THE CONFISCATION OF THE VEHICLE.
FINES ARE ALSO INFLICTED, ACCORDING TO CIRCUMSTANCES, FOR DRIVING WITHOUT A HELMET AND A
LICENSE PLATE, AS WELL AS FOR TAX EVASION (OMITTING TO PAY OWNERSHIP TAX).
DRIVING WITHOUT A DRIVING LICENSE IS A CRIMINAL OFFENSE.
9-3
YAMAHA MOTOR CO., LTD.
PRINTED IN FRANCE
2003.01
(E)
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