User manual YAMAHA AEROX50-2004

OWNER'S MANUAL YQ50 / YQ50L 5WJ-F8199-E0 EAU04576 INTRODUCTION Welcome to the Yamaha world of motorcycling! As the owner of the YQ50 or YQ50L, 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 YQ50 or YQ50L. 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! WARNING 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. CAUTION: 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 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS SCOOTER. EAUM0023 YQ50 or YQ50L OWNER'S MANUAL © 2002 by MBK INDUSTRIE 1st Edition, July 2002 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 2 3 4 5 6 7 8 9 GIVE SAFETY THE RIGHT OF WAY DESCRIPTION INSTRUMENT AND CONTROL FUNCTIONS PRE-OPERATION CHECKS OPERATION AND IMPORTANT RIDING POINTS PERIODIC MAINTENANCE AND MINOR REPAIR SCOOTER CARE AND STORAGE SPECIFICATIONS CONSUMER INFORMATION 1 2 3 4 5 6 7 8 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 EAU03099 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 pads 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. 1 1-2 EAU01161 DESCRIPTION Left view .............................................................................................. 2-1 Right view............................................................................................ 2-2 2 DESCRIPTION Left view 1 23 4 2 8 7 6 5 1. 2. 3. 4. Rear brake lever Left handlebar switches Speedometer Main switch/steering lock (page 3-5, 6-13, 6-16) (page 3-4) (page 3-3) (page 3-1, 3-9) 2-1 5. 6. 7. 8. Final transmission oil filler cap Centerstand Kick starter Air filter (page 6-7) (page 6-16) (page 3-7) (page 6-9) DESCRIPTION Right view 9 14 10 11 2 13 12 9. 10. 11. 12. Throttle grip Front brake lever Coolant tank location Battery/fuse 13. Oil tank cap location (page 6-11) (page 3-5, 6-13, 6-16) 14. Fuel tank cap (page 6-8) (page 6-18 - 6-20) 2-2 (page 3-8) (page 3-5) EAU00027 INSTRUMENT AND CONTROL FUNCTIONS Main switch / steering lock .................................................................. 3-1 Indicator and warning lights ................................................................ 3-2 Coolant temperature warning light ...................................................... 3-2 Speedometer unit ................................................................................ 3-3 Tachometer (depends on model) ........................................................ 3-3 Fuel gauge .......................................................................................... 3-3 Handlebar switches ............................................................................. 3-4 Front brake lever ................................................................................. 3-5 Rear brake lever .................................................................................. 3-5 Fuel tank cap ...................................................................................... 3-5 Fuel ..................................................................................................... 3-6 Catalytic converter .............................................................................. 3-7 Kick starter .......................................................................................... 3-7 2-stroke engine oil tank cap ................................................................ 3-8 2-stroke engine oil ............................................................................... 3-8 Starter (choke) lever ............................................................................ 3-9 Rider seat ............................................................................................ 3-9 Storage compartment A .................................................................... 3-10 Storage compartment B .................................................................... 3-11 Adjusting the shock absorber assembly (depends on model) ........... 3-11 3 INSTRUMENT AND CONTROL FUNCTIONS EAU00038 PUSH OFF " " All electrical systems are off. The key can be removed. EAU04470 WARNING EW000016 N 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. EAU00040 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 " ". 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. EAU00037 O PE LOCK " " The steering is locked, and all electrical systems are off. The key can be removed. To lock the steering 1. Turn the handlebars all the way to the left. 2. Push the key in from the " " 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 ON " " All electrical circuits are supplied with power, and the engine can be started. The key cannot be removed. NOTE : The headlight, meter lighting and taillight come on automatically when the engine is started. " INSTRUMENT AND CONTROL FUNCTIONS EAU02958 TEMP 123 ZAUM0254 1. Turn signal indicator light " 2. High beam indicator light " 3. Oil indicator light " " " " EAU03034 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. 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. CAUTION: EC000000 TEMP 1 ZAUM0255 3 " 1. Coolant temperature warning light " EAU01716 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 Coolant temperature warning light " " This warning light comes on when the engine overheats. When this occurs, stop the engine immediately and allow the engine to cool. EC000002 CAUTION: Do not operate the engine if it is overheated. High beam indicator light " " This indicator light comes on when the high beam of the headlight is switched on. Do not operate the scooter until you know that the engine oil level is sufficient. 3-2 INSTRUMENT AND CONTROL FUNCTIONS UK ONLY 1 1 2 1/2 E F 1 2 3 ZAUM0291 ZAUM0292 ZAUM0257 1. Speedometer 2. Odometer EAU00098 1. Tachometer 2. Red zone EAU00101 1. Fuel gauge EAU00113 Speedometer unit The speedometer unit is equipped with a speedometer and an odometer. The speedometer shows riding speed. The odometer shows the total distance traveled. Tachometer (Depends on model) The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. EC000003 Fuel gauge 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. CAUTION: Do not operate the engine in the tachometer red zone. Red zone: 10.000 r/min and above 3-3 INSTRUMENT AND CONTROL FUNCTIONS EAU03889 1 3 2 ZAUM0258 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. ZAUM0261 1 3 " 1. Start switch " EAU03888 1. Horn switch " " 2. Turn signal switch " 3. Dimmer switch " / / " " Dimmer switch " / " Set this switch to " " for the high beam and to " " for the low beam. EAU00118 EAUM0063 Handlebar switches EAU00129 Horn switch " " Press this switch to sound the horn. Start switch " " Push this switch while applying the front or rear brake to crank the engine with the starter. EC000005 CAUTION: See page 5-2 for starting instructions prior to starting the engine. 3-4 INSTRUMENT AND CONTROL FUNCTIONS 1 1 1 3 ZAUM0084 ZAUM0085 ZAUM0262 1. Front brake lever EAU03882 1. Rear brake lever EAU00163 1. Fuel tank cap EAU02935* 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. 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. Fuel tank cap To open the fuel tank cap Open the fuel tank cap lock cover, insert the key into the lock, and then turn it 1/4 turn counterclockwise. The lock will be released and the fuel tank cap can be opened. 3-5 INSTRUMENT AND CONTROL FUNCTIONS To close the fuel tank cap 1. Push the fuel tank cap into position with the key inserted in the lock. 2. Turn the key clockwise to the original position, remove it, and then close the lock cover. NOTE : The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked. WARNING EWA00025 1 2 EAU00185 EC000008 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU04206 ZAUM0020 3 1. Filler tube 2. Fuel level 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. WARNING EW000130 Recommended fuel: REGULAR UNLEADED GASOLINE ONLY Fuel tank capacity: Total amount: 7L 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. Make sure that the fuel tank cap is properly closed before riding. · · 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 INSTRUMENT AND CONTROL FUNCTIONS EAU03098 Catalytic converter This scooter is equipped with a catalytic converter in the muffler. EW000128 WARNING The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work. CAUTION: EC000114 3 ZAUM0289 EAUS0015 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. 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. · · · 3-7 INSTRUMENT AND CONTROL FUNCTIONS EAU03750 2-stroke engine oil 1 Make sure that there is sufficient oil in the 2-stroke engine oil tank. Add the recommended 2-stroke engine oil if necessary. 2 ZAUM0263 ZAUM0204 1. Storage compartment B 2. Oil tank cap EAUM0082 NOTE : Make sure that the 2-stroke engine oil tank cap is properly installed. 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 2-stroke engine oil tank cap The 2-stroke engine oil tank cap is located in the storage compartment. (See page 3-11 for storage compartment opening and closing procedures.) 1. To remove the 2-stroke engine oil tank cap, pull it off. 2. To install the 2-stroke engine oil tank cap, push it into the oil tank opening. NOTE : Make sure that the 2-stroke engine oil tank cap is properly installed before riding the scooter. 3-8 INSTRUMENT AND CONTROL FUNCTIONS 1 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. EAU03091 1 a 3 ZAUM0293 b ZAUM0264 1. Starter (choke) lever " " EAU03839 1. Seat Starter (choke) lever " " Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke). Move the lever in direction a to turn on the starter (choke). Move the lever in direction b to turn off the starter (choke). 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. 3. Fold the rider seat up. · · 3-9 INSTRUMENT AND CONTROL FUNCTIONS EC000010 CAUTION: 1 ZAUM0265 1. Storage compartment A EAU03450 Storage compartment A There is a storage compartment under the seat. (See page 3-9 for seat opening and closing procedures.) EWA00005 WARNING · · Do not exceed the load limit of 3.0 kg for the storage compartment. Do not exceed the maximum load of 180 kg for the vehicle. (Load is the totalweight of rider, passenger, cargo and accessories.) 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. 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. To store a helmet in the storage compartment, place the helmet upsidedown with the front facing forward. NOTE : Some helmets cannot be stored in the storage compartment because of their size or shape. Do not leave your scooter unattended with the seat open. · · · 3 · · · 3-10 INSTRUMENT AND CONTROL FUNCTIONS a 2 1 b Adjust the spring preload as follows. To increase the spring preload and thereby harden the suspension, turn the adjusting ring in direction a. To decrease the spring preload and thereby soften the suspension, turn the adjusting ring in direction b . · · 1 a 3 ZAUM0266 ZAUM0294 1. Storage compartment lock a Open EAUM0083 1. Spring preload adjusting ring 2. Position indicator EAU00295 Storage compartment B The storage compartment is located in front of the seat. To open the storage compartment 1. Insert the key into the lock, and then turn it clockwise. 2. Fold the storage compartment cover up. To close the storage compartment 1. Fold the storage compartment cover down. 2. Turn the key counterclockwise, and then remove it. Adjusting the shock absorber assembly (depends on model) This shock absorber assembly is equipped with a spring preload adjusting ring. EC000015 NOTE : Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber. Setting Minimum (soft) Standard Maximum (hard) b middle a CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. 3-11 INSTRUMENT AND CONTROL FUNCTIONS EAU00315 EW000041 WARNING This shock absorber contains highly pressurized nitrogen gas. For proper handling, read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. Do not tamper with or attempt to open the gas cylinder. Do not subject the shock absorber to an open flame or other high heat sources, otherwise it may explode due to excessive gas pressure. Do not deform or damage the gas cylinder in any way, as this will result in poor damping performance. Always have a Yamaha dealer service the shock absorber. 3 · · · · 3-12 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 Fuel · Check fuel level in fuel tank. · Refuel if necessary. · Check fuel line for leakage. · Check oil level in oil tank. · If necessary, add recommended oil to specified level. · Check vehicle for oil leakage. · Check vehicle for oil leakage. · Check coolant level in reservoir. · If necessary, add recommended coolant to specified level. · Check cooling system for leakage. · · · · · · · · · · 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. 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. CHECKS PAGE 3-5 -- 3-6 4 Two-stroke engine oil Final transmission oil Coolant 3-8, 6-15 6-7 6-8 Front brake 3-5, 6-13 -- 6-15 Rear brake 3-5, 6-13 -- 6-15 4-1 PRE-OPERATION CHECKS ITEM CHECKS · 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. · · · · Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. PAGE Throttle grip 6-11 Wheels and tires 6-11 -- 6-13 Brake levers Centerstand Chassis fasteners Instruments, lights signals and switches Battery · Make sure that operation is smooth. · Lubricate lever pivoting points if necessary. · Make sure that operation is smooth. · Lubricate pivot if necessary. · Make sure that all nuts, bolts and screws are properly tightened. · Tighten if necessary. · Check operation. · Correct if necessary. · Check fluid level. · Fill with distilled water if necessary. 6-13, 6-16 4 6-16 -- 3-3, 3-4, 6-20 -- 6-22 6-18 4-2 PRE-OPERATION CHECKS 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. WARNING EWA00033 If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the scooter. 4 4-3 EAU00372 OPERATION AND IMPORTANT RIDING POINTS Starting the engine .............................................................................. 5-1 Starting a warm engine ....................................................................... 5-2 Starting off........................................................................................... 5-2 Acceleration and deceleration ............................................................. 5-3 Braking ................................................................................................ 5-3 Tips for reducing fuel consumption ..................................................... 5-4 Engine break-in ................................................................................... 5-4 Parking ................................................................................................ 5-5 5 OPERATION AND IMPORTANT RIDING POINTS EAU01118 EW000129 · · 5 · WARNING 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. PUSH 3. Start the engine by pushing the start switch or by pushing the kickstarter lever down, while applying the front or rear brake. 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. 4. After starting the engine, move the starter (choke) lever back halfway. ECA00045 ZAUM0253 O PE N EAU00415* Starting the engine 1. Turn the key to " ", then when the oil level warning light comes on, turn it to " ". EC000045 CAUTION: If the oil level warning light does not come on, have a Yamaha dealer check the electrical circuit. 2. Turn the starter (choke) on and completely close the throttle. (See page 3-9 for starter (choke) operation.) CAUTION: For maximum engine life, never accelerate hard when the engine is cold! 5-1 OPERATION AND IMPORTANT RIDING POINTS EAU01258 5. When the engine is warm, turn the starter (choke) off. NOTE : The engine is warm when it responds normally to the throttle with the starter (choke) turned off. Starting a warm engine Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. ZAUM0267 EAU00433 Starting off NOTE : Before starting off, allow the engine to warm up. 1. While pulling the rear brake lever with your left hand and holding the grab bar with your right hand, push the scooter off the centerstand. 2. Sit astride the seat, and then adjust the rear view mirrors. 3. Switch the 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 5 OPERATION AND IMPORTANT RIDING POINTS · B A b a ZAUM0268 ZAUM0269 EAU00434 · EAU00435 5 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 . Braking 1. Close the throttle completely. 2. Apply both front and rear brakes simultaneously while gradually increasing the pressure. EW000057 · 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. WARNING · Avoid braking hard or suddenly (especially when leaning over to one side), otherwise the scooter may skid or overturn. 5-3 OPERATION AND IMPORTANT RIDING POINTS EAU03093 EAU00436 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). 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. EAUT0003 150 -- 500 km Avoid prolonged operation above 1/2 throttle. 500 -- 1,000 km Avoid cruising speeds in excess of 3/ 4 throttle. ECAT0001 · · · · CAUTION: 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. EC000049 5 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. CAUTION: If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle. 5-4 OPERATION AND IMPORTANT RIDING POINTS EAU00461 Parking When parking, stop the engine, and then remove the key from the main switch. WARNING EW000058 · 5 · 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 CAUTION: Never park in an area where there are fire hazards such as grass or other flammable materials. 5-5 EAU00462 PERIODIC MAINTENANCE AND MINOR REPAIR Periodic maintenance and lubrication chart ............ 6-2 Removing and installing cowling and panel ............ 6-5 Cowling A ................................................................ 6-5 Panel A .................................................................... 6-5 Checking the spark plug ......................................... 6-6 Final transmission oil .............................................. 6-7 Coolant .................................................................... 6-8 Cleaning the air filter element ................................. 6-9 Adjusting the carburetor ........................................ 6-10 Adjusting the throttle cable free play ..................... 6-11 Tires ...................................................................... 6-11 Wheels .................................................................. 6-13 Adjusting the front and rear brake lever free play ................................................................ 6-13 Checking the front and rear brake pads ................ 6-14 Checking the brake fluid level ............................... 6-14 Changing the brake fluid ....................................... 6-15 Adjusting the autolube pump ................................ 6-15 Checking and lubricating the cables ..................... 6-16 Lubricating the front and rear brakes levers .......... 6-16 Checking and lubricating the centerstand ............. 6-16 Checking the front fork .......................................... 6-17 Checking the steering ........................................... 6-17 Checking the wheel bearings ................................ 6-18 Battery................................................................... 6-18 Replacing the fuse ................................................ 6-20 Replacing a headlight bulb .................................... 6-20 Replacing tail/brake light bulb ............................... 6-21 Replacing a turn signal light bulb .......................... 6-22 Troubleshooting ..................................................... 6-22 Troubleshooting chart ............................................ 6-23 Engine overheating ............................................... 6-24 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 WARNING EAU00466 EW000061 WARNING If you are not familiar with scooter maintenance work, have a Yamaha dealer do it for you. 6 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. 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. 1 2 3 4 * * Fuel line Spark plug Air filter element Battery ITEM CHECK OR MAINTENANCE JOB · Check fuel hoses and vacuum hose for cracks or damage. · Replace. · Clean. · Replace. · Check electrolyte level and specific gravity. · Make sure that the breather hose is properly routed. · Check operation, fluid level and vehicle for fluid leakage. (See NOTE on page 6-4.) · Replace brake pads. 6 * Rear brake · Check operation, fluid level and vehicle for fluid leakage. (See NOTE on page 6-4.) · Replace brake pads. 7 8 * * Brake hoses Wheels · Check for cracks or damage. · Replace. (See NOTE on page 6-4.) · Check runout and for damage. 1 6 12 18 24 ANNUAL CHECK 6 5 * Front brake Whenever worn to the limit Whenever worn to the limit Every 4 years 6-2 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (x 1,000 km) NO. ITEM · · · · CHECK OR MAINTENANCE JOB Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. 1 6 12 18 24 ANNUAL CHECK 9 * Tires 10 * 11 * Wheel bearings Steering bearings · Check bearing for looseness or damage. · Check bearing play and steering for roughness. · Lubricate with lithium-soap-based grease. Every 24,000 km 12 * 13 Chassis fasteners Centerstand Front fork · Make sure that all nuts, bolts and screws are properly tightened. · Check operation. · Lubricate. · Check operation and for oil leakage.