User manual YAMAHA AEROX50-2006

OWNER'S MANUAL YQ50 / YQ50L 5WJ-F8199-E1 INTRODUCTION EAU10110 Welcome to the Yamaha world of motorcycling! As the owner of the YQ50/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/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! IMPORTANT MANUAL INFORMATION EAU34110 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. A NOTE provides key information to make procedures easier or clearer. CAUTION: NOTE: NOTE: G This manual should be considered a permanent part of this scooter and should remain with it even if the scooter is subsequently sold. G 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. EWA12410 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS SCOOTER. IMPORTANT MANUAL INFORMATION EAUM1010 YQ50/YQ50L OWNER'S MANUAL ©2004 by MBK INDUSTRIE 1st edition, August 2004 All rights reserved Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly prohibited. Printed in France. TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 Further safe-riding points ................1-4 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1 Main switch/steering lock ................3-1 Indicator and warning lights ............3-2 Speedometer unit ...........................3-3 Tachometer (Depends on models) ........................................3-3 Fuel gauge ......................................3-4 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 2-stroke engine oil tank ..................3-7 2-stroke engine oil ..........................3-8 Kickstarter .......................................3-8 Rider seat .......................................3-8 Storage compartment A...................3-9 Storage compartment B.................3-10 Adjusting the shock absorber assembly (Depends on models) ......................................3-10 PRE-OPERATION CHECKS ............. 4-1 Pre-operation check list .................. 4-2 OPERATION AND IMPORTANT RIDING POINTS................................. 5-1 Starting the engine .......................... 5-1 Starting off ...................................... 5-2 Acceleration and deceleration ........ 5-2 Braking ........................................... 5-3 Tips for reducing fuel consumption ............................... 5-3 Engine break-in .............................. 5-4 Parking ........................................... 5-4 PERIODIC MAINTENANCE AND MINOR REPAIR ................................. 6-1 Periodic maintenance and lubrication chart .......................... 6-2 Removing and installing the cowling and panel ....................... 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 Checking the throttle cable free play ........................................... 6-11 Tires ............................................. 6-11 Cast wheels .................................. 6-13 Checking the front and rear brake lever free play ........................... 6-13 Checking the front and rear brake pads .......................................... 6-14 Checking the brake fluid level ...... 6-15 Changing the brake fluid .............. 6-15 Checking and lubricating the throttle grip and cable ............... 6-16 Lubricating the front and rear brake 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 the headlight bulb ....... 6-21 Replacing the tail/brake light bulb ........................................... 6-21 Replacing a turn signal light bulb ........................................... 6-22 Troubleshooting ........................... 6-22 Troubleshooting charts ................ 6-23 SCOOTER CARE AND STORAGE... 7-1 Care ............................................... 7-1 Storage .......................................... 7-3 SPECIFICATIONS ............................ 8-1 CONSUMER INFORMATION............ 9-1 Identification numbers .................... 9-1 SAFETY INFORMATION EAUT1010 SCOOTERS ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS SCOOTER. HE OR SHE SHOULD: G OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF SCOOTER OPERATION. G OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER'S MANUAL. G OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES. G OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER'S MANUAL AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS. Safe riding G Always make pre-operation checks. Careful checks may help prevent an accident. G This scooter is designed to carry the operator and passenger. NOTE: Although this scooter is designed to carry a passenger, always comply with the local regulations. G G The failure of motorists to detect and recognize scooters in traffic is the predominating cause of automobile/scooter accidents. Many accidents have been caused by an automobile driver who did not see the scooter. Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident. Therefore: · Wear a brightly colored jacket. G · Use extra caution when approaching and passing through intersections, since intersections are the most likely places for scooter accidents to occur. · Ride where other motorists can see you. Avoid riding in another motorist's blind spot. Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current driver's license. · Make sure that you are qualified and that you only lend your scooter to other qualified operators. · Know your skills and limits. Staying within your limits may help you to avoid an accident. · We recommend that you practice riding your scooter where there is no traffic until you have become thoroughly familiar with the scooter and all of its controls. Many accidents have been caused by error of the scooter operator. A typical error made by the 1 1-1 SAFETY INFORMATION operator is veering wide on a turn due to EXCESSIVE SPEED or under cornering (insufficient lean angle for the speed). · Always obey the speed limit and never travel faster than warranted by road and traffic conditions. · Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control. · The operator should keep both hands on the handlebar and both feet on the footboard during operation to maintain control of the scooter. · The passenger should always hold onto the operator, the seat strap or grab bar, if equipped, with both hands and keep both feet on the passenger footrests. · Never carry a passenger unless he or she can firmly place both feet on the passenger footrests. Never ride under the influence of alcohol or other drugs. G This scooter is designed for onroad use only. It is not suitable for off-road use. G 1 G G Protective apparel The majority of fatalities from scooter accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries. G Always wear an approved helmet. G Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard. G The use of a jacket, substantial shoes, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations. G Never wear loose-fitting clothes, otherwise they could catch on the control levers or wheels and cause injury or an accident. G Never touch the engine or exhaust system during or after operation. They become very hot and can cause burns. Always wear protective clothing that covers your legs, ankles, and feet. Passengers should also observe the above precautions. Modifications Modifications made to this scooter not approved by Yamaha, or the removal of original equipment, may render the scooter unsafe for use and may cause severe personal injury. Modifications may also make your scooter illegal to use. Loading and accessories Adding accessories or cargo to your scooter can adversely affect stability and handling if the weight distribution of the scooter is changed. To avoid the possibility of an accident, use extreme caution when adding cargo or accessories to your scooter. Use extra care when riding a scooter that has added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding accessories to your scooter: 1-2 SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 180 kg (397 lb). When loading within this weight limit, keep the following in mind: G Cargo and accessory weight should be kept as low and close to the scooter as possible. Make sure to distribute the weight as evenly as possible on both sides of the scooter to minimize imbalance or instability. G Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely attached to the scooter before riding. Check accessory mounts and cargo restraints frequently. G Never attach any large or heavy items to the handlebar, front fork, or front fender. Such items can create unstable handling or a slow steering response. Accessories Genuine Yamaha accessories have been specifically designed for use on this scooter. Since Yamaha cannot test all other accessories that may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories. Keep the following guidelines in mind, as well as those provided under "Loading" when mounting accessories. G Never install accessories or carry cargo that would impair the performance of your scooter. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or reflectors. · Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. 1-3 G · Bulky or large accessories may seriously affect the stability of the scooter due to aerodynamic effects. Wind may attempt to lift the scooter, or the scooter may become unstable in cross winds. These accessories may also cause instability when passing or being passed by large vehicles. · Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability, therefore, such accessories are not recommended. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the scooter's electrical system an electric failure could result, which could cause a dangerous loss of lights or engine power. 1 SAFETY INFORMATION Gasoline and exhaust gas G GASOLINE IS HIGHLY FLAMMABLE: · Always turn the engine off when refueling. · Take care not to spill any gasoline on the engine or exhaust system when refueling. · Never refuel while smoking or in the vicinity of an open flame. G Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your scooter in an area that has adequate ventilation. G Always turn the engine off before leaving the scooter unattended and remove the key from the main switch. When parking the scooter, note the following: · The engine and exhaust system may be hot, therefore, park the scooter in a place where pedestrians or children are not likely to touch these hot areas. · Do not park the scooter on a slope or soft ground, otherwise it may fall over. · Do not park the scooter near a flammable source (e.g., a kerosene heater, or near an open flame), otherwise it could catch fire. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clothes. EAU10371 Further safe-riding points G G 1 G G G G G 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. 1-4 SAFETY INFORMATION G G 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 1-5 DESCRIPTION EAU10410 Left view 1 23 2 4 9 8 7 6 1. 2. 3. 4. 5. 6. 7. 8. Rear brake lever (page 3-5) Left handlebar switches (page 3-4) Speedometer unit (page 3-3) Main switch/steering lock (page 3-1) Final transmission oil filler cap (page 6-7) Centerstand (page 6-16) Kickstarter (page 3-8) Air filter element (page 6-9) 2-1 5 9. Coolant level check window (page 6-8) DESCRIPTION EAU10420 Right view 12 3 4 2 6 5 1. 2. 3. 4. 5. 6. Fuel tank cap (page 3-5) Throttle grip (page 6-11) Front brake lever (page 3-5) Coolant reservoir cap (page 6-8) Battery/fuse (page 6-18/6-20) Oil tank cap (page 3-7) 2-2 INSTRUMENT AND CONTROL FUNCTIONS EAU10460 EAU10660 EWA10060 Main switch/steering lock PE N OFF " " All electrical systems are off. The key can be removed. EAU10670 WARNING Never turn the key to " " or " " while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the vehicle is stopped before turning the key to " " or " ". O PUSH 3 ZAUM0253 CHECK " " The 2-stroke engine oil level warning light should come on. (See page 3-2.) EAU10680 The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU10640 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. 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. " 3-1 INSTRUMENT AND CONTROL FUNCTIONS EAU11002 Indicator and warning lights TEMP 123 ZAUM0254 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 2-stroke 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. ECA10010 EAU11430 Coolant temperature warning light "" 1/2 E F Km / h TEMP 3 1. Turn signal indicator light " 2. High beam indicator light " " 3. Oil level warning light " " " 1 ZAUM0255 EAU11020 1. Coolant temperature warning light " " Turn signal indicator light " " This indicator light flashes when the turn signal switch is pushed to the left or right. EAU11080 CAUTION: Do not operate the vehicle until you know that the engine oil level is sufficient. This warning light comes on when the engine overheats. When this occurs, stop the engine immediately and allow the engine to cool. ECA10020 High beam indicator light " " This indicator light comes on when the high beam of the headlight is switched on. EAU11180 CAUTION: Do not operate the engine if it is overheated. 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 3-2 INSTRUMENT AND CONTROL FUNCTIONS EAU11620 Speedometer unit 1 The speedometer unit is equipped with a speedometer and an odometer. The speedometer shows riding speed. The odometer shows the total distance traveled. EAU11851 Tachometer (Depends on models) 1 2 3 ZAUM0291 2 1. Speedometer 2. Odometer ZAUM0292 UK ONLY 1. Tachometer 2. Tachometer red zone 1 The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. ECA10031 CAUTION: 2 ZAUM0594 Do not operate the engine in the tachometer red zone. Red zone: 10000 r/min and above 1. Speedometer 2. Odometer 3-3 INSTRUMENT AND CONTROL FUNCTIONS EAU12140 EAU12343 EAU12460 Fuel gauge Handlebar switches Left 1/2 E F 1 1 3 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. 3 ZAUM0257 2 ZAUM0259 EAU12500 1. 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. 1. Horn switch " " 2. Turn signal switch " / " 3. Dimmer switch " / " Horn switch " " Press this switch to sound the horn. EAUM1131 Right Start switch " " Push this switch while applying the front or rear brake to crank the engine with the starter. ECA10050 CAUTION: 1 ZAUM0261 See page 5-1 for starting instructions prior to starting the engine. 1. Start switch " " EAU12400 Dimmer switch " / " Set this switch to " " for the high beam and to " " for the low beam. 3-4 INSTRUMENT AND CONTROL FUNCTIONS EAU12900 EAU12950 EAUM2080 Front brake lever 1 Rear brake lever 1 Fuel tank cap 1 3 ZAUM0084 ZAUM0085 ZAUM0262 1. Front brake lever 1. Rear brake lever 1. Fuel tank cap 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. To remove the fuel tank cap 1. Open the fuel tank cap lock cover. 2. Insert the key into the lock and turn it 1/4 turn counterclockwise. The lock will be released and the fuel tank cap can be removed. To install 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, and then remove it. 3. Close the lock cover. 3-5 INSTRUMENT AND CONTROL FUNCTIONS EAU13210 ECA10070 NOTE: The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. EWA11140 Fuel 1 2 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU13270 WARNING Make sure that the fuel tank cap is properly installed before riding. ZAUM0020 3 1. Fuel tank filler tube 2. Fuel level Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. EWA10880 Recommended fuel: REGULAR UNLEADED GASOLINE ONLY Fuel tank capacity: 7.0 L (1.85 US gal) (1.54 Imp.gal) WARNING G G Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands. Avoid spilling fuel on the hot engine. 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. 3-6 INSTRUMENT AND CONTROL FUNCTIONS EAU13440 EAUM1140 Catalytic converter This vehicle is equipped with a catalytic converter in the muffler. EWA10860 2-stroke engine oil tank 1 WARNING The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work. ECA10700 ZAUM0263 3 2 1. Storage compartment B 2. Oil tank cap ZAUM0204 CAUTION: The following precautions must be observed to prevent a fire hazard or other damages. G Use only unleaded gasoline. The use of leaded gasoline will cause unrepairable damage to the catalytic converter. G Never park the vehicle near possible fire hazards such as grass or other materials that easily burn. G Do not allow the engine to idle too long. To access the 2-stroke engine oil tank, open the storage compartment. (See page 3-10.) 1. Remove the 2-stroke engine oil tank cap by pulling it off. 2. Install the 2-stroke engine oil tank cap by pushing it into the oil tank opening. NOTE: Make sure that the 2-stroke engine oil tank cap is properly installed before riding the vehicle. 3-7 INSTRUMENT AND CONTROL FUNCTIONS EAU13460 EAUS1050 EAU14160 2-stroke engine oil Make sure that there is sufficient oil in the 2-stroke engine oil tank. Add the recommended 2-stroke engine oil if necessary. NOTE: Make sure that the 2-stroke engine oil tank cap is properly installed. Kickstarter 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 ZAUM0289 Recommended oil: Yamalube 2 or equivalent 2-stroke engine oil (JASO grade "FC", or ISO grades "EG-C" or "EG-D") Oil quantity: 1.4 L (1.48 US qt) (1.23 Imp.qt) 1. 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. 1 ZAUM0264 1. Seat To close the rider seat 1. Fold the rider seat down, and then push it down to lock it in place. 3-8 INSTRUMENT AND CONTROL FUNCTIONS 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 ZAUM0265 EAU14510 Storage compartment A 1 G G G 1. Storage compartment A There is a storage compartment under the seat. (See page 3-8.) EWA10960 WARNING G G G Do not exceed the load limit of 3.0 kg (6.6 lb) for the storage compartment. Do not exceed the maximum load of 180 kg (397 lb) for the vehicle. ECA10080 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: G Some helmets cannot be stored in the storage compartment because of their size or shape. G Do not leave your scooter unattended with the seat open. CAUTION: Keep the following points in mind when using the storage compartment. 3-9 INSTRUMENT AND CONTROL FUNCTIONS EAUM1170 EAU14830 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. Adjusting the shock absorber assembly (Depends on models) 1 2 (a) (b) crease the spring preload and thereby soften the suspension, turn the adjusting ring in direction (b). NOTE: Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber. 3 Spring preload setting: Minimum (soft): (b) Standard: middle Maximum (hard): (a) EWA10220 2 1 ZAUM0294 1. Spring preload adjusting ring 2. Position indicator ZAUM0266 1. Storage compartment lock 2. Open. This shock absorber assembly is equipped with a spring preload adjusting ring. ECA10100 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. G Do not tamper with or attempt to open the gas cylinder. 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. CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. Adjust the spring preload as follows. To increase the spring preload and thereby harden the suspension, turn the adjusting ring in direction (a). To de3-10 INSTRUMENT AND CONTROL FUNCTIONS G G 3 G 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. 3-11 PRE-OPERATION CHECKS EAU15591 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. NOTE: Pre-operation checks should be made each time the vehicle 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. EWA11150 WARNING If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the vehicle. 4 4-1 PRE-OPERATION CHECKS EAU15603 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 brake pads for wear. Replace if necessary. Check fluid level in reservoir. If necessary, add recommended brake fluid to specified level. Check hydraulic system for leakage. Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear. Replace if necessary. Check fluid level in reservoir. If necessary, add recommended brake fluid to specified level. Check hydraulic system for leakage. CHECKS PAGE 3-6 2-stroke engine oil Final transmission oil 3-7, 3-8 6-7 6-8 4 Coolant Front brake 6-13, 6-14, 6-15 Rear brake 6-13, 6-14, 6-15 Throttle grip · Make sure that operation is smooth. · Check cable free play. · If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. 6-11, 6-16 4-2 PRE-OPERATION CHECKS ITEM · · · · CHECKS Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. PAGE 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. 6-16 6-16 -- 4 -- 6-18 4-3 OPERATION AND IMPORTANT RIDING POINTS EAU15980 EAU16560 Starting the engine EWA10870 ECA10250 WARNING G CAUTION: 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 " ". N G 5 G 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. 3. While applying the front or rear brake, start the engine by pushing the start switch or by pushing the kickstarter lever down. PE PUSH O ZAUM0367 ZAUM0253 ECA10240 CAUTION: If the oil level warning light does not come on, have a Yamaha dealer check the electrical circuit. 2. Close the throttle completely. 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. 5-1 OPERATION AND IMPORTANT RIDING POINTS ECA11040 EAU16760 EAU16780 CAUTION: For maximum engine life, never accelerate hard when the engine is cold! 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. Acceleration and deceleration (b) (a) ZAUM0199 The speed can be adjusted by opening and closing the throttle. To increase the speed, turn the throttle grip in direction (a). To reduce the speed, turn the throttle grip in direction (b). ZAUM0267 5 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 OPERATION AND IMPORTANT RIDING POINTS EAU16791 Braking 1. Close the throttle completely. 2. Apply both front and rear brakes simultaneously while gradually increasing the pressure. G G 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. EAU16820 Tips for reducing fuel consumption Fuel consumption depends largely on your riding style. Consider the following tips to reduce fuel consumption: G Avoid high engine speeds during acceleration. G Avoid high engine speeds with no load on the engine. G 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). 5 ZAUM0269 EWA10300 WARNING G G Avoid braking hard or suddenly (especially when leaning over to one side), otherwise the scooter may skid or overturn. Railroad crossings, streetcar rails, iron plates on road construction sites, and manhole covers become extremely slippery when wet. Therefore, slow 5-3 OPERATION AND IMPORTANT RIDING POINTS EAU16830 ECAM1070 EAU17212 Engine break-in There is never a more important period in the life of your engine than the period between 0 and 1000 km (600 mi). For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1000 km (600 mi). The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided. EAUM2090 CAUTION: After 1000 km (600 mi) of operation, the final transmission oil must be changed. 1000 km (600 mi) and beyond Avoid prolonged full throttle operation. Vary speeds occasionally. ECA10270 Parking When parking, stop the engine, and then remove the key from the main switch. EWA10310 WARNING G CAUTION: If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle. G 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 vehicle may overturn. ECA10380 5 CAUTION: 0­150 km (0­90 mi) Avoid prolonged operation above 1/3 throttle. Vary the speed of the scooter from time to time. Do not operate it at one set throttle position. 150­500 km (90­300 mi) Avoid prolonged operation above 1/2 throttle. 500­1000 km (300­600 mi) Avoid cruising speeds in excess of 3/4 throttle. 5-4 Never park in an area where there are fire hazards such as grass or other flammable materials. PERIODIC MAINTENANCE AND MINOR REPAIR EAU17291 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 vehicle inspection, adjustment, and lubrication are explained on the following pages. EWA10320 WARNING If you are not familiar with maintenance work, have a Yamaha dealer do it for you. 6 6-1 PERIODIC MAINTENANCE AND MINOR REPAIR EAU17710 Periodic maintenance and lubrication chart NOTE: G The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. G From 30000 km, repeat the maintenance intervals starting from 6000 km. G Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km) NO. 1 * Fuel line 2 3 Spark plug Air filter element ITEM CHECK OR MAINTENANCE JOB 1 · Check fuel and vacuum hoses 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. · Replace brake pads. · Check operation, fluid level and vehicle for fluid leakage. · Replace brake pads. · Check for cracks or damage. · Replace. · Check runout and for damage. 6 12 18 24 ANNUAL CHECK 6 4 * Battery 5 * Front brake Whenever worn to the limit 6 * Rear brake Whenever worn to the limit 7 * Brake hoses 8 * Wheels Every 4 years 6-2 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) NO. ITEM · · · · CHECK OR MAINTENANCE JOB 1 Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. 6 12 18 24 ANNUAL CHECK 9 * Tires 10 * Wheel bearings 11 * Steering bearings 12 * Chassis fasteners 13 Centerstand · Check bearing for looseness or damage. · Check bearing play and steering for roughness. · Lubricate with lithium-soap-based grease. · Make sure that all nuts, bolts and screws are properly tightened. · Check operation. · Lubricate. · Check operation and for oil leakage. · Check operation and shock absorber for oil leakage. · Adjust engine idling speed. · Check operation. · Bleed if necessary. · Check coolant level and vehicle for coolant leakage. · Change. · Check vehicle for oil leakage. · Change. · Replace. · Check operation. Every 24000 km Every 10000 km 14 * Front fork 6 15 * Shock absorber assembly 16 * Carburetor 17 * Autolube pump 18 * Cooling system Every 3 years 19 Final transmission oil 20 * V-belt Front and rear brake 21 * switches 6-3 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) NO. ITEM Moving parts and cables Throttle grip housing and cable Lights, signals and switches CHECK OR MAINTENANCE JOB 1 22 · Lubricate. · Check operation and free play. · Adjust the throttle cable free play if necessary. · Lubricate the throttle grip housing and cable. · Check operation. · Adjust headlight beam. 6 12 18 24 ANNUAL CHECK EAUM2070 23 * 24 *