Yamaha Vino125 Yj125s Service Manual

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5YR-F8199-10LIT-11626-17-43

YJ125S

OWNER’S MANUAL

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INTRODUCTION

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Congratulations on your purchase of the Yamaha VINO125. This model is the result of Yamaha’s vast experience in theproduction of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship andreliability that have made Yamaha a leader in these fields.

This manual will give you an understanding of the operation, inspection, and basic maintenance of this scooter. If you haveany questions concerning the operation or maintenance of your scooter, please consult a Yamaha dealer.

The design and manufacture of this Yamaha scooter fully comply with the emissions standards for clean air applicable at thedate of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of thescooter. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to therecommended maintenance schedules and operating instructions contained within this manual.

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IMPORTANT MANUAL INFORMATION

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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 scooteroperator, 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.

NOTE:8 This manual should be considered a permanent part of this scooter and should remain with it even if the scooter is

subsequently sold.8 Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most

current product information available at the time of printing, there may be minor discrepancies between your scooter andthis manual. If you have any questions concerning this manual, please consult your Yamaha dealer.

EWA12410

wPLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS SCOOTER.

w

cC

NOTE:

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IMPORTANT MANUAL INFORMATION

VINO125OWNER’S MANUAL

©2003 by Yamaha Motor Taiwan Co., Ltd.1st edition, November 2003

All rights reserved.Any reprinting or unauthorized usewithout the written permission ofYamaha Motor Taiwan Co., Ltd.

is expressly prohibited.Printed in Taiwan.

P/N LIT-11626-17-43

AFFIX DEALER

LABEL HERE

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TABLE OF CONTENTS

SAFETY INFORMATION ....... 1-1Further safe-riding points ..... 1-5Location of important labels .. 1-6

DESCRIPTION ....................... 2-1Left view ............................... 2-1Right view ............................. 2-2Controls and instruments ..... 2-3

INSTRUMENT AND CONTROLFUNCTIONS........................... 3-1

Main switch/steering lock ..... 3-1Indicator lights ...................... 3-2Handlebar switches .............. 3-2Speedometer unit ................. 3-3Fuel gauge ............................ 3-3Front brake lever .................. 3-3Rear brake lever ................... 3-4Fuel tank cap ........................ 3-4Fuel ...................................... 3-5Catalytic converter ............... 3-5Kickstarter ............................ 3-6Seat ...................................... 3-6Helmet holder ....................... 3-6Storage compartment ........... 3-7Luggage hook ....................... 3-8Carrier .................................. 3-8Sidestand ............................. 3-8

Ignition circuit cut-off system 3-9PRE-OPERATION CHECKS . 4-1

Pre-operation check list ........ 4-2OPERATION AND IMPORTANTRIDING POINTS .................... 5-1

Starting a cold engine ........... 5-1Starting off ............................ 5-2Acceleration and

deceleration ....................... 5-2Braking ................................. 5-3Engine break-in .................... 5-3Parking ................................. 5-4

PERIODIC MAINTENANCEAND MINOR REPAIR ............ 6-1

PERIODIC MAINTENANCE 6-1Owner’s tool kit ..................... 6-1Periodic maintenance chart for

the emission controlsystem ............................... 6-2

General maintenance andlubrication chart ................. 6-3

Removing and installingpanels ................................ 6-6

Checking the spark plug....... 6-7Air filter and V-belt case air filter

elements ............................ 6-8

Replacing the tail/brake lightbulb .................................. 6-11

Replacing a turn signal lightbulb .................................. 6-11

Checking the front brake padsand rear brake shoes ...... 6-12

Checking the brake fluidlevel ................................. 6-13

Changing the brake fluid ..... 6-13Checking and lubricating the

cables .............................. 6-14Checking and lubricating the

throttle grip and cable ...... 6-14Lubricating the front and rear

brake levers ..................... 6-14Checking and lubricating the

centerstand andsidestand ......................... 6-15

Checking the front fork ....... 6-15Checking the steering ........ 6-16Replacing the headlight

bulb .................................. 6-16Final transmission oil .......... 6-17Adjusting the carburetor ..... 6-19Adjusting the throttle cable free

play .................................. 6-19

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TABLE OF CONTENTS

Tires ................................... 6-19Cast wheels ....................... 6-21Adjusting the brake lever free

play .................................. 6-21Adjusting the rear brake lever

free play ........................... 6-21Battery ................................ 6-22Replacing the fuse .............. 6-23Engine oil and oil strainer .... 6-24Troubleshooting .................. 6-26Troubleshooting chart ......... 6-27

SCOOTER CARE AND STOR-AGE ........................................ 7-1

Care...................................... 7-1Storage ................................. 7-3

SPECIFICATIONS ................. 8-1CONSUMER INFORMATION 9-1

Identification numbers .......... 9-1Reporting safety defects ...... 9-3Motorcycle noise regulation .. 9-4YAMAHA MOTOR CORPORA-

TION, U.S.A STREET ANDENDURO MOTORCYCLELIMITED WARRANTY ....... 9-5

YAMAHA EXTENDED SER-VICE (Y.E.S.) ..................... 9-7

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QQQQQ SAFETY INFORMATION

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SCOOTERS ARE SINGLE TRACK VE-HICLES. THEIR SAFE USE AND OP-ERATION ARE DEPENDENT UPONTHE USE OF PROPER RIDING TECH-NIQUES AS WELL AS THE EXPER-TISE OF THE OPERATOR. EVERY OP-ERATOR SHOULD KNOW THE FOL-LOWING REQUIREMENTS BEFORERIDING THIS SCOOTER.HE OR SHE SHOULD:8 OBTAIN THOROUGH INSTRUC-

TIONS FROM A COMPETENTSOURCE ON ALL ASPECTS OFSCOOTER OPERATION.

8 OBSERVE THE WARNINGS ANDMAINTENANCE REQUIRE-MENTS IN THE OWNER’SMANUAL.

8 OBTAIN QUALIFIED TRAINING INSAFE AND PROPER RIDINGTECHNIQUES.

8 OBTAIN PROFESSIONAL TECH-NICAL SERVICE AS INDICATEDBY THE OWNER’S MANUAL AND/OR WHEN MADE NECESSARYBY MECHANICAL CONDITIONS.

Safe riding8 Always make pre-operation checks.

Careful checks may help preventan accident.

8 This scooter is designed to carrythe operator and passenger.

8 The failure of motorists to detectand recognize scooters in traffic isthe predominating cause of auto-mobile/scooter accidents. Manyaccidents have been caused by anautomobile driver who did not seethe scooter. Making yourself con-spicuous appears to be very effec-tive in reducing the chance of thistype of accident.

Therefore:9 Wear a brightly colored jacket.9 Use extra caution when

approaching and passingthrough intersections, sinceintersections are the mostlikely places for scooteraccidents to occur.

9 Ride where other motorists cansee you. Avoid riding in anothermotorist’s blind spot.

8 Many accidents involve inexperi-enced operators. In fact, many op-erators who have been involved inaccidents do not even have a cur-rent driver’s license.9 Make sure that you are quali-

fied and that you only lend yourscooter to other qualifiedoperators.

9 Know your skills and limits.Staying within your limits mayhelp you to avoid an accident.

9 We recommend that youpractice riding your scooterwhere there is no traffic untilyou have become thoroughlyfamiliar with the scooter and allof its controls.

Many accidents have been causedby error of the scooter operator. Atypical error made by the operatoris veering wide on a turn due toEXCESSIVE SPEED orundercornering (insufficient leanangle for the speed).9 Always obey the speed limit

and never travel faster thanwarranted by road and trafficconditions.

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9 Always signal before turning orchanging lanes. Make sure thatother motorists can see you.

8 The posture of the operator andpassenger is important for propercontrol.9 The operator should keep both

hands on the handlebar andboth feet on the footboardduring operation to maintaincontrol of the scooter.

9 The passenger should alwayshold onto the operator, the seatstrap or grab bar, if equipped,with both hands and keep bothfeet on the passenger foot-rests.

9 Never carry a passenger unlesshe or she can firmly place bothfeet on the passenger foot-rests.

8 Never ride under the influence ofalcohol or other drugs.This scooter is designed for on-roaduse only. It is not suitable for off-road use.

Protective apparelThe majority of fatalities from scooteraccidents are the result of head injuries.The use of a safety helmet is the singlemost critical factor in the prevention orreduction of head injuries.8 Always wear an approved helmet.8 Wear a face shield or goggles. Wind

in your unprotected eyes could con-tribute to an impairment of visionwhich could delay seeing a hazard.

8 The use of a jacket, substantialshoes, trousers, gloves, etc., iseffective in preventing or reducingabrasions or lacerations.

8 Never wear loose-fitting clothes,otherwise they could catch on thecontrol levers or wheels and causeinjury or an accident.

8 Never touch the engine or exhaustsystem during or after operation.They become very hot and cancause burns. Always wear protec-tive clothing that covers your legs,ankles, and feet.

8 Passengers should also observethe above precautions.

ModificationsModifications made to this scooter notapproved by Yamaha, or the removal oforiginal equipment, may render thescooter unsafe for use and may causesevere personal injury. Modificationsmay also make your scooter illegal touse.Loading and accessoriesAdding accessories or cargo to yourscooter can adversely affect stabilityand handling if the weight distribution ofthe scooter is changed. To avoid thepossibility of an accident, use extremecaution when adding cargo or accesso-ries to your scooter. Use extra care whenriding a scooter that has added cargo oraccessories. Here are some generalguidelines to follow if loading cargo oradding accessories to your scooter:

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LoadingThe total weight of the operator, passen-ger, accessories and cargo must not ex-ceed the maximum load limit of 144 kg(317 lb). When loading within this weightlimit, keep the following in mind:8 Cargo and accessory weight should

be kept as low and close to thescooter as possible. Make sure todistribute the weight as evenly aspossible on both sides of thescooter to minimize imbalance orinstability.

8 Shifting weights can create a sud-den imbalance. Make sure that ac-cessories and cargo are securelyattached to the scooter before riding.Check accessory mounts andcargo restraints frequently.

8 Never attach any large or heavyitems to the handlebar, front fork,or front fender. Such items can cre-ate unstable handling or a slowsteering response.

AccessoriesGenuine Yamaha accessories havebeen specifically designed for use onthis scooter. Since Yamaha cannot testall other accessories that may be avail-able, you must personally be responsiblefor the proper selection, installation anduse of non-Yamaha accessories. Useextreme caution when selecting and in-stalling any accessories.Keep the following guidelines in mind,as well as those provided under “Load-ing” when mounting accessories.8 Never install accessories or carry

cargo that would impair the perfor-mance of your scooter. Carefullyinspect the accessory before us-ing it to make sure that it does notin any way reduce ground clear-ance or cornering clearance, limitsuspension travel, steering travelor control operation, or obscurelights or reflectors.9 Accessories fitted to the

handlebar or the front fork areacan create instability due toimproper weight distribution oraerodynamic changes. If

accessories are added to thehandlebar or front fork area,they must be as lightweight aspossible and should be kept toa minimum.

9 Bulky or large accessories mayseriously affect the stability ofthe scooter due to aerodynamiceffects. Wind may attempt tolift the scooter, or the scootermay become unstable in crosswinds. These accessories mayalso cause instability whenpassing or being passed bylarge vehicles.

9 Certain accessories candisplace the operator from hisor her normal riding position.This improper position limitsthe freedom of movement ofthe operator and may limitcontrol ability, therefore, suchaccessories are not recom-mended.

8 Use caution when adding electricalaccessories. If electrical accesso-ries exceed the capacity of thescooter’s electrical system an elec-

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tric failure could result, which couldcause a dangerous loss of lights orengine power.

Gasoline and exhaust gas8 GASOLINE IS HIGHLY FLAM-

MABLE:9 Always turn the engine off

when refueling.9 Take care not to spill any

gasoline on the engine orexhaust system when refueling.

9 Never refuel while smoking orin the vicinity of an open flame.

8 Never start the engine or let it runfor any length of time in a closedarea. The exhaust fumes are poi-sonous and may cause loss of con-sciousness and death within ashort time. Always operate yourscooter in an area that has adequateventilation.

8 Always turn the engine off beforeleaving the scooter unattended andremove the key from the mainswitch. When parking the scooter,note the following:

9 The engine and exhaustsystem may be hot, therefore,park the scooter in a placewhere pedestrians or childrenare not likely to touch these hotareas.

9 Do not park the scooter on aslope or soft ground, otherwiseit may fall over.

9 Do not park the scooter near aflammable source (e.g., akerosene heater, or near anopen flame), otherwise it couldcatch fire.

8 If you should swallow any gasoline,inhale a lot of gasoline vapor, orallow gasoline to get into your eyes,see your doctor immediately. If anygasoline spills on your skin or cloth-ing, immediately wash the affectedarea with soap and water andchange your clothes.

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Further safe-riding points

ZAUM00**

Turn left

ZAUM00**

Turn right

8 Make sure to signal clearly whenmaking turns.

8 Braking can be extremely difficulton a wet road. Avoid hard braking,because the scooter could slide.Apply the brakes slowly when stop-ping on a wet surface.

8 Slow down as you approach a cor-ner or turn. Once you have com-pleted a turn, accelerate slowly.

8 Be careful when passing parkedcars. A driver might not see you andopen a door in your path.

8 Railroad crossings, streetcar rails,iron plates on road constructionsites, and manhole covers becomeextremely slippery when wet. Slowdown and cross them with caution.Keep the scooter upright, otherwiseit could slide out from under you.

8 The brake lining could get wet whenyou wash the scooter. After wash-ing the scooter, check the brakesbefore riding.

8 Always wear a helmet, gloves, trou-sers (tapered around the cuff andankle so they do not flap), and abright colored jacket.

8 Do not carry too much luggage onthe scooter. An overloaded scooter

is unstable. Use a strong cord tosecure any luggage to the carriers.A loose load will affect the stabilityof the scooter and could divert yourattention from the road. (See page1-2.)

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Location of important labelsPlease read the following important labels carefully before operating this vehicle.

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DESCRIPTION

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Left view

1. Front wheel (page 6-19)2. Front turn signal light (page 3-2)3. Luggage hook (page 3-8)4. Helmet holder (page 3-6)5. Storage compartment (page 3-7)6. Rear turn signal light (page 3-2)7. Rear wheel (page 6-19)8. Rear brake lever free play adjusting nut (page 6-21)9. Kickstarter (page 3-6)10.Air filter element (page 6-8)11.Battery (page 6-22)

DESCRIPTION

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91011

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DESCRIPTION

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Right view

12.Tail/brake light (page6-11)13.Carrier (page3-8)14.Fuel tank cap (page 3-4)15.Seat (page 3-6)16.Brake master cylinder (page 6-13)17.Headlight (page 6-16)18.Front brake caliper (page 6-12)19.Spark plug (page 6-7)20.Centerstand (page 6-15)21.Muffler (page 3-5)

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192021

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DESCRIPTION

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Controls and instruments

22.Rear brake lever (page 3-4)23.Left handlebar switches (page 3-2)24.Speedometer unit (page 3-3)25.Right handlebar switches (page 3-2)26.Front brake lever (page 3-3)27.Throttle grip (page 6-19)28.Main switch / steering lock (page 3-1)29.Fuel gauge (page 3-3)

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INSTRUMENT AND CONTROL FUNCTIONS

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Main switch/steering lock

ZAUM00**

The main switch/steering lock controlsthe ignition and lighting systems, and isused to lock the steering. The variouspositions are described below.

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ZAUM00**

1. Push

EAU10530

ONAll electrical circuits are supplied withpower, the taillight comes on, and theengine can be started. The key cannotbe removed.

NOTE:The headlight and meter lighting comeon automatically when the engine isstarted.

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OFFAll electrical systems are off. The keycan be removed.


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LOCKThe steering is locked, and all electricalsystems are off. The key can be re-moved.

To lock the steering1. Turn the handlebars all the way to

the left.2. Push the key in from the “OFF” po-

sition, and then turn it to “LOCK”while still pushing it.

3. Remove the key.

To unlock the steeringPush the key in, and then turn it to “OFF”while still pushing it.

EWA10060

wNever turn the key to “OFF” or“LOCK” while the vehicle is moving,otherwise the electrical systems willbe switched off, which may result inloss of control or an accident. Makesure that the vehicle is stopped be-fore turning the key to “OFF” or“LOCK”.

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ZAUM00**

1. Turn2. Release

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Indicator lightsEAU11020

Turn signal indicator light “55555”This indicator light flashes when the turnsignal switch is pushed to the left or right.

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ZAUM00**

1. High beam indicator light ”&”2. Turn indicator light “5”

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High beam indicator light “&&&&&”This indicator light comes on when thehigh beam of the headlight is switchedon.

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Engine stop switch “#####/$$$$$”Set this switch to “#” before startingthe engine. Set this switch to “$” to stopthe engine in case of an emergency, suchas when the motorcycle overturns orwhen the throttle cable is stuck.

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ZAUM00**

1. Engine stop switch “#/$“2. Start switch “,”

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Start switch “,,,,,”Push this switch while applying the frontor rear brake to crank the engine withthe starter.

ECA10050

cCSee page 5-1 for starting instructionsprior to starting the engine.

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Handlebar switchesEAU12400

Dimmer switch “%%%%%/&&&&&”Set this switch to “&” for the high beamand to “%” for the low beam.

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ZAUM00**

1. Dimmer switch “%/&“2. Turn signal switch “4/6”3. Horn switch “*”

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Turn signal switch “44444/66666”To signal a right-hand turn, push thisswitch to “4”. To signal a left-hand turn,push this switch to “6”. When released,the switch returns to the center position.To cancel the turn signal lights, push theswitch in after it has returned to the cen-ter position.

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Horn switch “*****”Press this switch to sound the horn.

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Speedometer unit

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ZAUM00**

1. Speedometer

The speedometer unit is equipped witha speedometer and an odometer. Thespeedometer shows riding speed. Theodometer shows the total distance trav-eled.

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Fuel gauge

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ZAUM00**

1. Fuel gauge

The fuel gauge indicates the amount offuel in the fuel tank. The needle movestowards “E” (Empty) as the fuel leveldecreases. When the needle reaches thered line, refuel as soon as possible.

NOTE:Do not allow the fuel tank to empty it-self completely.

EAU12900

Front brake lever

1

ZAUM00**

1. Front brake lever

The front brake lever is located on theright handlebar grip. To apply the frontbrake, pull this lever toward the handle-bar grip.

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EAU32430

Recommended fuel:REGULAR UNLEADED GASO-LINE ONLY

Fuel tank capacity:4.5 L (1.18 US gal) (0.98 Imp.gal)

Your Yamaha engine has been designedto use regular unleaded gasoline with apump octane number [(R+M)/2] of 86 orhigher, or a research octane number of91 or higher. If knocking (or pinging) oc-curs, use a gasoline of a different brandor a gasoline or premium unleaded fuel.Use of unleaded fuel will extend sparkplug life and reduce maintenance cost.

GasoholThere are two types of gasohol: gaso-hol containing ethanol and that contain-ing methanol. Gasohol containing etha-nol can be used if ethanol content doesnot exceed 10%. Gasohol containingmethanol is not recommended byYamaha because it can cause damageto the fuel system or vehicle perfor-mance problems.

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Fuel tank cap

12

ZAUM00**

1. Fuel tank cap cover2. Match mark

To remove the fuel tank capSlide the lock cover open, insert the keyinto the lock, and then turn it 1/4 turnclockwise. The lock will be released andthe fuel tank cap can be removed.

To install the fuel tank cap1. Insert the fuel tank cap into the tank

opening with the key inserted in thelock and with the marks on the capand tank aligned.

2. Turn the key counterclockwise tothe original position, remove it, andthen close the lock cover.

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Rear brake lever

1

ZAUM00**

1. Rear brake lever

The rear brake lever is located on theleft handlebar grip. To apply the rearbrake, pull this lever toward the handle-bar grip.

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Fuel

1

ZAUM00**

1. Fuel tank filler tube

Make sure that there is sufficient fuel inthe tank. Fill the fuel tank to the bottomof the filler tube as shown.

EAU13440

Catalytic converterThis vehicle is equipped with a catalyticconverter in the muffler.

EWA10860

wThe exhaust system is hot after op-eration. Make sure that the exhaustsystem has cooled down before do-ing any maintenance work.

ECA10700

cCThe following precautions must beobserved to prevent a fire hazard orother damages.88888 Use only unleaded gasoline. The

use of leaded gasoline will causeunrepairable damage to the cata-lytic converter.

88888 Never park the vehicle near pos-sible fire hazards such as grassor other materials that easilyburn.

88888 Do not allow the engine to idletoo long.

NOTE:The fuel tank cap cannot be installedunless the key is in the lock. In addi-tion, the key cannot be removed if thecap is not properly installed and locked.

EWA10130

wMake sure that the fuel tank cap isproperly installed before riding.

EWA10880

w88888 Do not overfill the fuel tank, oth-

erwise it may overflow when thefuel warms up and expands.

88888 Avoid spilling fuel on the hotengine.

ECA10070

cCImmediately wipe off spilled fuel witha clean, dry, soft cloth, since fuel maydeteriorate painted surfaces or plas-tic parts.

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Seat

OPEN

ZAUM00**

To open the seat1. 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 seat up.

To close the seat1. Fold the seat down, and then push

it down to lock it in place.2. Remove the key from the main

switch if the scooter will be left un-attended.

EAU14300

Helmet holder

1

ZAUM00**

1. Helmet holder (x2)

The helmet holder is located under theseat.

To secure a helmet to the helmetholder

1. Open the seat. (See page 3-6.)2. Attach the helmet to the helmet

holder, and then securely close theseat.

EAU13680

Kickstarter

1ZAUM00**

1. Kickstarter

To star t the engine, fold out thekickstarter lever, move it down lightlywith your foot until the gears engage,and then push it down smoothly butforcefully.

NOTE:Make sure that the seat is properly se-cured before riding.

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Storage compartment

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ZAUM00**

1. Storage compartment

There is a storage compartment underthe seat. (See page 3-6.)

EWA10960

w88888 Do not exceed the load limit of 5

kg (11 lb) for the storage com-partment.

88888 Do not exceed the maximumload of 144 kg (317 lb) for the ve-hicle.

ECA10080

cCKeep the following points in mindwhen using the storage compart-ment.88888 Since the storage compartment

accumulates heat when exposedto the sun, do not store anythingsusceptible to heat inside it.

88888 To avoid humidity from spread-ing through the storage compart-ment, wrap wet articles in a plas-tic bag before storing them in thecompartment.

88888 Since the storage compartmentmay get wet while the scooter isbeing washed, wrap any articlesstored in the compartment in aplastic bag.

88888 Do not keep anything valuable orbreakable in the storage com-partment.

To store a helmet in the storage com-partment, place the helmet upside-downwith the front facing forward.

EWA10160

wNever ride with a helmet attached tothe helmet holder, since the helmetmay hit objects, causing loss of con-trol and possibly an accident.

To release the helmet from the hel-met holder

Open the seat, remove the helmet fromthe helmet holder, and then close theseat.

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EAU15110

Carrier

1

ZAUM00**

1. rear carrierEWA10170


kg (7 lb) for the carrier.88888 Do not exceed the maximum

load of 144 kg (317 lb) for the ve-hicle.

EAU15300

SidestandThe sidestand is located on the left sideof the frame. Raise the sidestand orlower it with your foot while holding themotorcycle upright.

NOTE:The built-in sidestand switch is part ofthe ignition circuit cut-off system, whichcuts the ignition in certain situations.(See further down for an explanation ofthe ignition circuit cut-off system.)

EWA10240

wThe vehicle must not be ridden withthe sidestand down, or if thesidestand cannot be properly movedup (or does not stay up), otherwisethe sidestand could contact theground and distract the operator, re-sulting in a possible loss of control.Yamaha’s ignition circuit cut-off sys-tem has been designed to assist theoperator in fulfilling the responsibil-ity of raising the sidestand beforestarting off. Therefore, check this sys-

EAUT1070

Luggage hook

1

ZAUM00**

1. Luggage hookEWAT1030


kg (7 lb) for the luggage hook.88888 Do not exceed the maximum

load of 144 kg (317 lb) for the ve-hicle.

NOTE:8 Some helmets cannot be stored in

the storage compartment becauseof their size or shape.

8 Do not leave your scooter unat-tended with the seat open.

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EAU15371

Ignition circuit cut-off systemThe ignition circuit cut-off system (com-prising the sidestand switch and brakelight switches) has the following func-tions.8 It prevents star ting when the

sidestand is up, but neither brakeis applied.

8 It prevents starting when eitherbrake is applied, but the sidestandis still down.

8 It cuts the running engine when thesidestand is moved down.

Periodically check the operation of theignition circuit cut-off system accordingto the following procedure.

EWA10250

wIf a malfunction is noted, have aYamaha dealer check the system be-fore riding.

tem regularly as described below andhave a Yamaha dealer repair it if itdoes not function properly.

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NOTE:This check is most reliable if performed with a warmed-up engine.

The sidestand switch may be defective.The scooter should not be ridden until checked by aYamaha dealer.

The brake switch may be defective.The scooter should not be ridden until checked by aYamaha dealer.

The sidestand switch may be defective.The scooter should not be ridden until checked by aYamaha dealer.

With the engine turned off:1. Move the sidestand down.2. Make sure that the engine stop switch is turned on.3. Turn the key on.4. Keep the front or rear brake applied.5. Push the start switch.

Does the engine start?

With the engine still off:6. Move the sidestand up.7. Keep the front or rear brake applied.8. Push the start switch.

Does the engine start?

With the engine still running:9. Move the sidestand down.

Does the engine stall?

The system is OK. The scooter can be ridden.

NO YES

YES NO

YES NO

5YR-F8199-10ch3.pmd 2003/10/27, 19:3210

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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 lossof tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-tion, 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 shorttime; and the added safety it assures is more than worth the time involved.

EWA11150

wIf any item in the Pre-operation check list is not working properly, have it inspected and repaired before operatingthe vehicle.


5YR-F8199-10ch4.pmd 2003/10/27, 19:321

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EAU15602

Pre-operation check list

ITEM CHECKS PAGE

Fuel• Check fuel level in fuel tank.• Refuel if necessary.• Check fuel line for leakage.

3-2, 3-5

Engine oil• Check oil level in engine.• If necessary, add recommended oil to specified level.• Check vehicle for oil leakage.

6-24

Final transmission oil • Check vehicle for oil leakage. 6-17

Front brake

• 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 the brake pads for wear.

6-12~6-13, 6-21

Rear brake

• Check operation.• Lubricate cable if necessary.• Check lever free play.• Adjust if necessary.

6-21

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.

6-19

Wheels and tires

• Check for damage.• Check tire condition and tread depth.• Check air pressure.• Correct if necessary.

6-19

Brake levers • Make sure that operation is smooth.• Lubricate lever pivoting points if necessary. 6-14

Centerstand, sidestand • Make sure that operation is smooth.• Lubricate pivots if necessary. 6-15

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Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened.• Tighten if necessary. -

Instruments, lights, signals and switches

• Check operation. • Correct if necessary. 3-2~3-3

Engine stop switch • Check operation. 3-2

Sidestand switch • Check operation of ignition circuit cut-off system.• If system is defective, have Yamaha dealer check vehicle. 3-8~3-10

ITEM CHECKS PAGE

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OPERATION AND IMPORTANT RIDING POINTS

EAU16590

Starting a cold engine

ZAUM00**

ECA10250

cCSee page 5-3 for engine break-in in-structions prior to operating the ve-hicle for the first time.

In order for the ignition circuit cut-offsystem to enable starting, the sidestandmust be up.

EWA10290

w88888 Before starting the engine, check

the function of the ignition cir-cuit cut-off system according tothe procedure described on page3-8.

88888 Never ride with the sidestanddown.

1. Turn the key to “ON” and make surethat the engine stop switch is setto “#”.

2. Close the throttle completely.3. Start the engine by pushing the

start switch while applying the frontor rear brake.

NOTE:If the engine does not start, release thestart switch, wait a few seconds, andthen try again. Each starting attemptshould be as short as possible to pre-serve the battery. Do not crank the en-gine more than 10 seconds on any oneattempt. If the engine does not start, trywith the throttle open 1/8 turn.

ECA11130

cCFor maximum engine life, alwayswarm the engine up before startingoff. Never accelerate hard when theengine is cold!


EAU15980EWA10870

w88888 Become thoroughly familiar with

all operating controls and theirfunctions before riding. Consulta Yamaha dealer regarding anycontrol or function that you donot thoroughly understand.

88888 Never start the engine or operateit in a closed area for any lengthof time. Exhaust fumes are poi-sonous, and inhaling them cancause loss of consciousness anddeath within a short time. Alwaysmake sure that there is adequateventilation.

88888 For safety, always start the enginewith the centerstand down.

5YR-F8199-10ch5.pmd 2003/10/27, 19:331

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EAU16770

Starting off

ZAUM00**

NOTE:Before starting off, allow the engine towarm up.

1. While pulling the rear brake leverwith your left hand and holding thecarrier with your right hand, pushthe scooter off the centerstand.

2. Sit astride the seat, and then ad-just the rear view mirrors.

3. Switch the turn signal on.4. Check for oncoming traffic, and

then slowly turn the throttle grip (onthe right) in order to take off.

5. Switch the turn signal off.

EAU16780

Acceleration and deceleration

a

b0

10

MPH

20

3040

50

60

70

800

20

40

6080

100

120

a

b

ZAUM00**

The speed can be adjusted by openingand closing the throttle. To increase thespeed, turn the throttle grip in directiona. To reduce the speed, turn the throttlegrip in direction b.

1

ZAUM00**

1. Start switch “,”

2ZAUM00**

2. Kickstarter

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EAU16791

Braking

1 2

ZAUM00**

1. Rear2. Front

1. Close the throttle completely.2. Apply both front and rear brakes si-

multaneously while gradually in-creasing the pressure.

EWA10300

w88888 Avoid braking hard or suddenly

(especially when leaning over toone side), otherwise the scootermay skid or overturn.

88888 Railroad crossings, streetcarrails, iron plates on road con-struction sites, and manhole cov-ers become extremely slippery

EAU16830

Engine break-inThere is never a more important periodin the life of your engine than the periodbetween 0 and 1000 km (600 mi). Forthis reason, you should read the follow-ing material carefully.

Since the engine is brand new, do notput an excessive load on it for the first1000 km (600 mi). The various parts inthe engine wear and polish themselvesto the correct operating clearances. Dur-ing this period, prolonged full-throttleoperation or any condition that mightresult in engine overheating must beavoided.

when wet. Therefore, slow downwhen approaching such areasand cross them with caution.

88888 Keep in mind that braking on awet road is much more difficult.

88888 Ride slowly down a hill, as brak-ing downhill can be very difficult.

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EAU16990

0~500 km (0~300 mi)Avoid prolonged operation above 1/3throttle.

500~1000 km (300~600 mi)Avoid prolonged operation above 1/2throttle.

ECA11500

cCAfter 1000 km (600 mi) of operation,the engine oil must be changed, andthe oil filter element and the oilstrainer cleaned.

1000 km (600 mi) and beyondThe vehicle can now be operated nor-mally.

ECA10270

cCIf any engine trouble should occurduring the engine break-in period,immediately have a Yamaha dealercheck the vehicle.

EAU17211

Parking

When parking, stop the engine, and thenremove the key from the main switch.

EWA10310

w88888 Since the engine and exhaust

system can become very hot,park in a place where pedestri-ans or children are not likely totouch them.

88888 Do not park on a slope or on softground, otherwise the vehiclemay overturn.

ECA10380

cCNever park in an area where there arefire hazards such as grass or otherflammable materials.

5YR-F8199-10ch5.pmd 2003/10/27, 19:334

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17370

Owner’s tool kit

1

ZAUM00**

1. Owner’s tool kit

EAU17222


The owner’s tool kit is located under theseat. (See page 3-6.)The service information included in thismanual and the tools provided in theowner’s tool kit are intended to assistyou in the performance of preventivemaintenance and minor repairs. How-ever, additional tools such as a torquewrench may be necessary to performcertain maintenance work correctly.

NOTE:If you do not have the tools or experi-ence required for a particular job, havea Yamaha dealer perform it for you.

EWA10340

wModifications not approved byYamaha may cause loss of perfor-mance, excessive emissions, and ren-der the vehicle unsafe for use. Con-sult a Yamaha dealer before attempt-ing any changes.

EAU17231

Safety is an obligation of the owner.Periodic inspection, adjustment and lu-brication will keep your vehicle in thesafest and most efficient condition pos-sible. The most important points of mo-torcycle inspection, adjustment, and lu-brication are explained on the followingpages.Maintenance, replacement, or repairof the emission control devices andsystems may be performed by anyrepair establishment or individual thatis certified (if applicable).

EWA10320

wIf you are not familiar with mainte-nance work, have a Yamaha dealer doit for you.

EAU17300

PERIODIC MAINTENANCEPROPER PERIODIC MAINTENANCEOF YOUR MOTORCYCLE IS IMPOR-TANT IN ORDER TO ENJOY LONG,PLEASURABLE SERVICE. ESPE-CIALLY IMPORTANT ARE THE MAIN-TENANCE SERVICES RELATED TOEMISSIONS CONTROL. THESE CON-TROLS NOT ONLY FUNCTION TO EN-

SURE CLEANER AIR, BUT ARE ALSOVITAL TO PROPER ENGINE OPERA-TION AND MAXIMUM PERFOR-MANCE. IN THE FOLLOWING PERI-ODIC MAINTENANCE CHARTS, THESERVICES RELATED TO EMISSIONSCONTROL ARE GROUPED SEPA-RATELY. THESE SERVICES REQUIRESPECIALIZED DATA, KNOWLEDGE,AND EQUIPMENT. YAMAHA DEALERSARE TRAINED AND EQUIPPED TOPERFORM THESE PARTICULAR SER-VICES.

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EAU17560*

Periodic maintenance chart for the emission control system

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

NOTE:From 10000 mi (16000 km) or 30 months, repeat the maintenance intervals starting from 2000 mi (4000 km) or 6 months.

NO. ITEM ROUTINE

ODOMETER READING

600 mi (1,000 km)or1

month

2,000 mi (4,000 km)or6

months

4,000 mi (7,000 km)or12

months

6,000 mi (10,000

km)or18

months

8,000 mi (13,000

km)or24

months

1 * Fuel line • Check fuel hoses and vacuum hose for cracks or damage.

2 * Valves • Check valve clearance.• Adjust if necessary.

3 * Spark plug• Check condition.• Clean and regap.

• Replace.

4 * Air filter element• Clean.

• Replace.

5 *Crankcase breather system

• Check breather hose for cracks or damage.• Replace if necessary.

6 * Carburetor • Adjust engine idling speed.

7 * Exhaust system• Check for leakage.• Tighten if necessary.• Replace gaskets if necessary.

8 *Evaporative emission control system

• Checkcontrol system for damage.• Replace if necessary.

9 * Air induction system • Check the air cut-off valve, reed valve, and hose for damage.• Replace any damaged.

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EAU32121

General maintenance and lubrication chart

NO. ITEM ROUTINE

ODOMETER READING

600 mi (1,000 km)or1

month

2,000 mi (4,000 km)or6

months

4,000 mi (7,000 km)or12

months

6,000 mi (10,000

km)or18

months

8,000 mi (13,000

km)or24

months

1 *V-belt case air filter elements

• Clean.

• Replace.

2 * Front brake• Check operation, fluid level and vehicle for fluid leakage.

(See NOTE on page 6-5.)

• Replace brake pads. Whenever worn to the limit

3 * Rear brake• Check operation and adjust brake lever free play.

• Replace brake shoes. Whenever worn to the limit

4 * Brake hose• Check for cracks or damage.

• Replace. (See NOTE on page 6-5.) Every 4 years

5 * Wheels • Check runout and for damage.

6 * Tires

• Check tread depth and for damage.• Replace if necessary.• Check air pressure.• Correct if necessary.

7 * Wheel bearings • Check bearing for looseness or damage.

8 * Steering bearings• Check bearing play and steering for roughness.

• Lubricate with lithium-soap-based grease. Every 16,000 mi (24,000 km)

9 * Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened.

10 Sidestand, centerstand • Check operation.• Lubricate.

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* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

NOTE:From 12000 mi (18000 km) or 36 months, repeat the maintenance intervals starting from 4000 mi (7000 km) or 12 months.

11 * Sidestand switch • Check operation.

12 * Front fork • Check operation and for oil leakage.

13 * Shock absorber assembly • Check operation and shock absorber for oil leakage.

14 Engine oil • Change.• Check oil level and vehicle for leakage. Every 1,900 mi (3,000 km)

15 * Engine oil filter element • Clean.

16 * Engine oil strainer • Clean.

17 Final transmission oil • Change.

18 * V-belt • Replace. Every 12,000 mi (18,000 km)

19 *Front and rear brake switches • Check operation.

20 Moving parts and cables • Lubricate.

21 *Throttle grip housing and cable

• Check operation and free play.• Adjust the throttle cable free play if necessary.• Lubricate the throttle grip housing and cable.

22 *Lights, signals and switches

• Check operation.• Adjust headlight beam.

NO. ITEM ROUTINE

ODOMETER READING

600 mi (1,000 km)or1

month

2,000 mi (4,000 km)or6

months

4,000 mi (7,000 km)or12

months

6,000 mi (10,000

km)or18

months

8,000 mi (13,000

km)or24

months

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EAU17620

NOTE:8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.8 Hydraulic brake system

9 When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluidlevel regularly and fill as required.

9 Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.9 Replace the brake hoses every four years or if cracked or damaged.

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8

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EAU19210

Panel A

1

2

ZAUM00**

1. Panel A2. Screw (x2)

To remove the panelRemove the screws, and then take thepanel off.

To install the panelPlace the panel in the original position,and then install the screws.

EAU19210

Panel B

1

2

ZAUM00**

1. Panel B2. Screw (x2)

To remove the panelRemove the screws, and then take thepanel off.

To install the panelPlace the panel in the original position,and then install the screws.

EAU18771

Removing and installing pan-els

1

2ZAUM00**

1. Panel A2. Panel B

The panels shown above need to be re-moved to perform some of the mainte-nance jobs described in this chapter.Refer to this section each time a panelneeds to be removed and installed.

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EAUT1170

Checking the spark plug

1

ZAUM00**

1. Spark plug cap

The spark plug is an important enginecomponent, which is easy to check.Since heat and deposits will cause anyspark plug to slowly erode, the sparkplug should be removed and checked inaccordance with the periodic mainte-nance and lubrication chart. In addition,the condition of the spark plug can re-veal the condition of the engine.

To remove the spark plug1. Remove panel A. (See page 6-6.)2. Remove the spark plug cap.3. Remove the spark plug as shown,

with the spark plug wrench includedin the owner’s tool kit.

To check the spark plug1. Check that the porcelain insulator

around the center electrode of thespark plug is a medium-to-light tan(the ideal color when the vehicle isridden normally).

NOTE:If the spark plug shows a distinctly dif-ferent color, the engine could be defec-tive. Do not attempt to diagnose suchproblems yourself. Instead, have aYamaha dealer check the vehicle.

2. Check the spark plug for electrodeerosion and excessive carbon orother deposits, and replace it if nec-essary.

Specified spark plug:CR7E (NGK)

To install the spark plug1. Measure the spark plug gap with a

wire thickness gauge and, if nec-essary, adjust the gap to specifi-cation.

1

ZAUM0037

1. Spark plug gap

Spark plug gap:0.7~0.8 mm (0.028~0.032 in)

2. Clean the surface of the spark pluggasket and its mating surface, andthen wipe off any grime from thespark plug threads.

3. Install the spark plug with the sparkplug wrench, and then tighten it tothe specified torque.

Tightening torque:Spark plug:

13 Nm (1.3m • kgf, 9.4ft • lbf)

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NOTE:If a torque wrench is not available wheninstalling a spark plug, a good estimateof the correct torque is 1/4~1/2 turn pastfinger tight. However, the spark plugshould be tightened to the specifiedtorque as soon as possible.

4. Install the spark plug cap.5. Install the panel.

EAUT1301

Air filter and V-belt case air fil-ter elementsAir filter and V-belt case air filterThe air filter and V-belt case air filter el-ements should be cleaned at the inter-vals specified in the periodic mainte-nance and lubrication chart. Clean bothfilter elements more frequently if you areriding in unusually wet or dusty areas.

Cleaning the air filter element1. Place the scooter on the

centerstand.

1

ZAUM00**

1. Air filter case cover

2. Remove the air filter case cover byremoving the screw.

1ZAUM00**

1. Air filter element

3. Pull the air filter element out, andthen blow the dirt out with com-pressed air as shown.

4. Check the air filter element for dam-age and replace it if necessary.

5. Insert the air filter element into theair filter case.

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8

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1ZAUM00**

1. Compressed airECA10480

cC88888 Make sure that the air filter ele-

ment is properly seated in the airfilter case.

88888 The engine should never be op-erated without the air filter ele-ment installed, otherwise thepiston(s) and/or cylinder(s) maybecome excessively worn.

6.Install the air filter case cover by in-stalling the screw.

Cleaning the V-belt case air filter ele-ment

1. Remove the kickstarter lever by re-moving the bolt.

2. Remove the crankcase cover by re-moving the screws.

2

1

3ZAUM00**

1. Kickstarter2. Bolt3. Crankcase cover

3. Remove the filter element holder byremoving the screw.

4. Pull the air filter element out, andthen clean it with solvent. Aftercleaning, remove the remainingsolvent by squeezing the element.

1

2

ZAUM00**

1. Filter element holder2. Filter element

EWA10430

wUse only a dedicated parts cleaningsolvent. To avoid the risk of fire orexplosion, do not use gasoline orsolvents with a low flash point.

ECA10520

cCTo avoid damaging the air filter ele-ment, handle it gently and carefully,and do not twist it.

5. Apply oil of the recommended typeto the entire surface of the spongematerial, and then squeeze the ex-cess oil out.

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2

3

4

5

6

7

8

9


NOTE:The air filter element should be wet butnot dripping.

Recommended oil:Engine oil

6. Insert the element into the air filtercase.

7. Install the filter element holder byinstalling the screw.

8. Install the crankcase cover by in-stalling the screws.

9. Install the kickstarter lever by in-stalling the bolt, then tightening thebolt to the specified torque.

Tightening torque:Kickstarter bolt:

23 Nm (2.3m • kgf, 16.6ft • lbf)

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9


EAU24201

Replacing a turn signal lightbulb

1

2

ZAUM00**

1. Front light lens2. Bulb

2

1

ZAUM00**

1. Rear light lens2. Bulb

EAU24131

Replacing the tail/brake lightbulb

12

ZAUM00**

1. Light lens2. Bulb

1. Remove the tail/brake light lens byremoving the screws.

2. Remove the defective bulb by push-ing it in and turning it counterclock-wise.

3. Insert a new bulb into the socket,push it in, and then turn it clock-wise until it stops.

4. Install the lens by installing thescrews.

ECA10680

cCDo not overtighten the screws, other-wise the lens may break.

1. Remove the turn signal light lensby removing the screw.

2. Remove the defective bulb by push-ing it in and turning it counterclock-wise.

3. Insert a new bulb into the socket,push it in, and then turn it clock-wise until it stops.

4. Install the lens by installing thescrew.

ECA11190

cCDo not overtighten the screw, other-wise the lens may break.

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3

4

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EAU22410

Front brake pads

21

3

ZAUM00**

1. Wear indicator2. Brake disk3. Brake pads

Each front brake pad is provided with awear indicator, which allows you tocheck the brake pad wear without hav-ing to disassemble the brake. To checkthe brake pad wear, check the positionof the wear indicator while applying thebrake. If a brake pad has worn to thepoint that the wear indicator almosttouches the brake disc, have a Yamahadealer replace the brake pads as a set.

EAU22540

Rear brake shoes

1

2ZAUM00**

1. Wear indicator2. Wear limit line

The rear brake is provided with a wearindicator, which allows you to check thebrake shoe wear without having to dis-assemble the brake. To check the brakeshoe wear, check the position of thewear indicator while applying the brake.If a brake shoe has worn to the pointthat the wear indicator reaches the wearlimit line, have a Yamaha dealer replacethe brake shoes as a set.

EAU22380

Checking the front brake padsand rear brake shoesThe front brake pads and the rear brakeshoes must be checked for wear at theintervals specified in the periodic main-tenance and lubrication chart.

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1

2

3

4

5

6

7

8

9


EAU32341

Checking the brake fluid level

LOWER MIN

1

ZAUM00**

1. Minimum level mark

Insufficient brake fluid may allow air toenter the brake system, possibly caus-ing it to become ineffective.

Before riding, check that the brake fluidis above the minimum level mark andreplenish if necessary. A low brake fluidlevel may indicate worn brake pads and/or brake system leakage. If the brakefluid level is low, be sure to check thebrake pads for wear and the brake sys-tem for leakage.

Observe these precautions:8 When checking the fluid level,

make sure that the top of the mas-ter cylinder is level by turning thehandlebars.Use only the recommended qual-ity brake fluid, otherwise the rub-ber seals may deteriorate, causingleakage and poor braking perfor-mance.

Recommended brake fluid:DOT 4

8 Refill with the same type of brakefluid. Mixing fluids may result in aharmful chemical reaction and leadto poor braking performance.

8 Be careful that water does not en-ter the master cylinder when refill-ing. Water will significantly lower theboiling point of the fluid and mayresult in vapor lock.

8 Brake fluid may deteriorate paintedsurfaces or plastic parts. Alwaysclean up spilled fluid immediately.

8 As the brake pads wear, it is nor-mal for the brake fluid level togradually go down. However, if the

EAU22720

Changing the brake fluidHave a Yamaha dealer change the brakefluid at the intervals specified in theNOTE after the periodic maintenanceand lubrication chart. In addition, havethe oil seals of the brake master cylin-der and caliper as well as the brake hosereplaced at the intervals listed below orwhenever they are damaged or leaking.8 Oil seals: Replace every two years.8 Brake hose: Replace every four

years.

brake fluid level goes down sud-denly, have a Yamaha dealer checkthe cause.

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EAU23090

Checking and lubricating thecablesThe operation of all control cables andthe condition of the cables should bechecked before each ride, and thecables and cable ends should be lubri-cated if necessary. If a cable is dam-aged or does not move smoothly, havea Yamaha dealer check or replace it.

Recommended lubricant:Yamaha Chain and Cable Lube orengine oil SAE 10W-30 (API SE)

EWA10710

wDamage to the outer housing ofcables may result in internal rustingand cause interference with cablemovement. Replace damaged cablesas soon as possible to prevent un-safe conditions.

EAU23110

Checking and lubricating thethrottle grip and cableThe operation of the throttle grip shouldbe checked before each ride. In addi-tion, the cable should be lubricated orreplaced at the intervals specified in theperiodic maintenance chart.

EAU23170

Lubricating the front and rearbrake levers

ZAUM00**

The pivoting points of the front and rearbrake levers must be lubricated at theintervals specified in the periodic main-tenance and lubrication chart.

Recommended lubricant:Lithium-soap-based grease (all-pur-

pose grease)

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EAU23210

Checking and lubricating thecenterstand and sidestand

ZAUM00**

The operation of the centerstand andsidestand should be checked beforeeach ride, and the pivots and metal-to-metal contact surfaces should be lubri-cated if necessary.

EWA10740

wIf the centerstand or sidestand doesnot move up and down smoothly,have a Yamaha dealer check or repairit.

Recommended lubricant:Lithium-soap-based grease (all-pur-

pose grease)

EAU23271

Checking the front fork

ZAUM00**

The condition and operation of the frontfork must be checked as follows at theintervals specified in the periodic main-tenance and lubrication chart.

To check the conditionEWA10750

wSecurely support the motorcycle sothat there is no danger of it fallingover.

Check the inner tubes for scratches,damage and excessive oil leakage.

To check the operation1. Place the motorcycle on a level sur-

face and hold it in an upright posi-tion.

2. While applying the front brake, pushdown hard on the handlebars sev-eral times to check if the front forkcompresses and reboundssmoothly.

ECA10590

cCIf any damage is found or the frontfork does not operate smoothly, havea Yamaha dealer check or repair it.

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EAU23280

Checking the steering

ZAUM00**

Worn or loose steering bearings maycause danger. Therefore, the operationof the steering must be checked as fol-lows at the intervals specified in theperiodic maintenance and lubricationchart.

1. Place a stand under the engine toraise the front wheel off the ground.

EWA10750

wSecurely support the motorcycle sothat there is no danger of it fallingover.

EAU23780

Replacing the headlight bulb

1

ZAUM00**

1. Headlight unit

This model is equipped with a quartzbulb headlight. If the headlight bulb burnsout, replace it as follows.

1. Remove the headlight unit by re-moving the screws.

2. Hold the lower ends of the front forklegs and try to move them forwardand backward. If any free play canbe felt, have a Yamaha dealer checkor repair the steering.

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EAU20060

Final transmission oilThe final transmission case must bechecked for oil leakage before each ride.If any leakage is found, have a Yamahadealer check and repair the scooter. Inaddition, the final transmission oil mustbe changed as follows at the intervalsspecified in the periodic maintenanceand lubrication chart.

1. Start the engine, warm it up byriding the scooter for several min-utes, and then stop the engine.

2. Place the scooter on thecenterstand.

3. Place an oil pan under the finaltransmission case to collect theused oil.

1

ZAUM00**

1. Final transmission oil filler cap

2

1

ZAUM00**

1. Headlight coupler2. Bulb cover

2. Disconnect the headlight coupler,and then remove the bulb cover.

1

ZAUM00**

1. Bulb holder

3. Remove the headlight bulb holderby turning it counterclockwise, andthen remove the defective bulb.

EWA10790

wHeadlight bulbs get very hot. There-fore, keep flammable products awayfrom a lit headlight bulb, and do nottouch the bulb until it has cooleddown.

4. Place a new headlight bulb into po-sition, and then secure it with thebulb holder.

ECA10660

cCDo not touch the glass part of theheadlight bulb to keep it free from oil,otherwise the transparency of theglass, the luminosity of the bulb, andthe bulb life will be adversely affected.Thoroughly clean off any dirt and fin-gerprints on the headlight bulb us-ing a cloth moistened with alcoholor thinner.

5. Install the headlight bulb cover, andthen connect the coupler.

6. Install the headlight unit by install-ing the screws.

7. Have a Yamaha dealer adjust theheadlight beam if necessary.

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1

ZAUM00**

1. Final transmission gear oil drain bolt

4. Remove the oil filler cap and drainbolt to drain the oil from the finaltransmission case.

5. Install the final transmission oildrain bolt, and then tighten it to thespecified torque.

Tightening torque:Final transmission oil drain bolt:

23 Nm (2.3m • kgf, 16.6ft • lbf)

6. Add the specified amount of therecommended final transmissionoil, and then install and tighten theoil filler cap.

Recommended final transmissionoil:See page 8-1.

Oil quantity:0.13 L (0.14 US qt) (0.1 Imp.qt)

EWA11310

w88888 Make sure that no foreign mate-

rial enters the final transmissioncase.

88888 Make sure that no oil gets on thetire or wheel.

7. Check the final transmission casefor oil leakage. If oil is leaking,check for the cause.

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EAU21250

Adjusting the carburetorThe carburetor is an important part ofthe engine and its emission control sys-tem, which requires very sophisticatedadjustment. Therefore, carburetor adjust-ments should be left to Yamaha dealer,who has the necessary professionalknowledge and experience.

EAU21380

Adjusting the throttle cablefree play

a

ZAUM00**

a.1.5 ~ 3.5mm

The throttle cable free play should mea-sure 1.5~3.5 mm (0.06~0.14 in) at thethrottle grip. Periodically check thethrottle cable free play and, if necessary,have a Yamaha dealer adjust it.

EAU21860

Tires

1

2

ZAUM0054

1. Tread depth2. Side wall

To maximize the performance, durabil-ity, and safe operation of your scooter,note the following points regarding thespecified tires.

Tire air pressureThe tire air pressure should be checkedand, if necessary, adjusted before eachride.

EWA10500

w88888 The tire air pressure must be

checked and adjusted on coldtires (i.e., when the temperature

of the tires equals the ambienttemperature).

88888 The tire air pressure must beadjusted in accordance with theriding speed and with the totalweight of rider, passenger, cargo,and accessories approved for thismodel.

EWA10510

wProper loading of your vehicle is im-portant for several characteristics ofyour vehicle, such as handling, brak-ing, performance and safety. Do notcarry loosely packed items that canshift. Securely pack your heaviest

Tire air pressure(measured on cold tires)

Load* Front Rear

Up to 90 kg (198 lb)150 kPa1.50 kgf/cm2

22 psi

200 kPa2.0 kgf/cm2

29 psi

90 kg (198 lb)–maximum

150 kPa1.50kgf/cm2

22psi

225 kPa2.25 kgf/cm2

32 psi

Maximum load* 144 kg (317 lb)

* Total weight of rider, passenger, cargo and accessories

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items close to the center of the mo-torcycle, and distribute the weightevenly from side to side. Properlyadjust the suspension for your load,and check the condition and pressureof your tires. NEVER OVERLOADYOUR VEHICLE. Make sure that thetotal weight of the cargo, rider, pas-senger, and accessories (cowling,saddlebags, etc. if approved for thismodel) does not exceed the maxi-mum load of the vehicle. Operationof an overloaded motorcycle couldcause tire damage, an accident, oreven injury.

Tire inspectionThe tires must be checked before eachride. If a tire tread shows crosswise lines(minimum tread depth), if the tire has anail or glass fragments in it, or if thesidewall is cracked, have a Yamahadealer replace the tire immediately.

Minimum tire tread depth (front andrear):0.8 mm (0.03 in)

NOTE:The tire tread depth limits may differ fromcountry to country. Always comply withthe local regulations.

Tire informationThis scooter is equipped with castwheels and tubeless tires with valves.

EWA10590

wOperating the scooter with exces-sively worn tires decrease riding sta-bility and can lead to loss of control.Have excessively worn tires replacedby a Yamaha dealer immediately.Brakes, tires, and related wheel partsreplacement should be left to aYamaha Service Technician.

EWA10580

w88888 It is dangerous to ride with a

worn-out tire. When a tire treadbegins to show crosswise lines,have a Yamaha dealer replace thetire immediately.

88888 The replacement of all wheel-and brake-related parts, includ-ing the tires, should be left to aYamaha dealer, who has the nec-essary professional knowledgeand experience.

FRONT

Manufacturer Size Model

Cheng shin 3.50-10 51J

REAR

Manufacturer Size Model

Cheng shin 3.50-10 51J

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EAU21960

Cast wheelsTo maximize the performance, durabil-ity, and safe operation of your motor-cycle, note the following points regard-ing the specified wheels.8 The wheel rims should be checked

for cracks, bends or warpage be-fore each ride. If any damage isfound, have a Yamaha dealer re-place the wheel. Do not attempteven the smallest repair to thewheel. A deformed or cracked wheelmust be replaced.

8 The wheel should be balancedwhenever either the tire or wheelhas been changed or replaced. Anunbalanced wheel can result in poorperformance, adverse handlingcharacteristics, and a shortenedtire life.

8 Ride at moderate speeds afterchanging a tire since the tire sur-face must first be “broken in” for itto develop its optimal characteris-tics.

EAU22100

Adjusting the brake lever freeplay

1

ZAUM0107

1. Free play

The brake lever free play should mea-sure 2~5 mm (0.08~0.2 in) as shown.Periodically check the brake lever freeplay and, if necessary, have a Yamahadealer adjust it.

EWA10640

wAn incorrect brake lever free play in-dicates a hazardous condition in thebrake system. Do not operate themotorcycle until the brake system hasbeen checked or repaired by aYamaha dealer.

EAU22170

Adjusting the rear brake leverfree play

1

ZAUM0108

1. Free play

b

a

1

ZAUM00**

1. Adjusting nut

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The brake lever free play should mea-sure 10~20 mm (0.4~0.8 in) as shown.Periodically check the brake lever freeplay and, if necessary, adjust it as fol-lows.To increase the brake lever free play,turn the adjusting nut at the brake shoeplate in direction (a). To decrease thebrake lever free play, turn the adjustingnut in direction (b).

EWA10650

wIf proper adjustment cannot be ob-tained as described, have a Yamahadealer make this adjustment.

EAUT1230

Battery

1

ZAUM00**

1. Battery

This model is equipped with a sealed-type (MF) battery, which does not re-quire any maintenance. There is no needto check the electrolyte or to add dis-tilled water.

ECA10620

cCNever attempt to remove the batterycell seals, as this would permanentlydamage the battery.

EWA10760

w88888 Electrolyte is poisonous and dan-

gerous since it contains sulfuricacid, which causes severe burns.Avoid any contact with skin, eyesor clothing and always shieldyour eyes when working nearbatteries. In case of contact, ad-minister the following FIRST AID.99999 EXTERNAL: Flush with

plenty of water.99999 INTERNAL: Drink large

quantities of water or milkand immediately call aphysician.

99999 EYES: Flush with water for15 minutes and seek promptmedical attention.

88888 Batteries produce explosive hy-drogen gas. Therefore, keepsparks, flames, cigarettes, etc.,away from the battery and pro-vide sufficient ventilation whencharging it in an enclosed space.

88888 KEEP THIS AND ALL BATTERIESOUT OF THE REACH OF CHIL-DREN.

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The battery is located under thefootboard. Remove panel B to accessthe battery. (See page 6-6.)

To charge the batteryHave a Yamaha dealer charge the bat-tery as soon as possible if it seems tohave discharged. Keep in mind that thebattery tends to discharge more quicklyif the vehicle is equipped with optionalelectrical accessories.

To store the battery1. If the vehicle will not be used for

more than one month, remove thebattery, fully charge it, and thenplace it in a cool, dry place.

2. If the battery will be stored for morethan two months, check it at leastonce a month and fully charge it ifnecessary.

3. Fully charge the battery before in-stallation.

4. After installation, make sure thatthe battery leads are properly con-nected to the battery terminals.

ECA10630

cC88888 Always keep the battery charged.

Storing a discharged battery cancause permanent battery dam-age.

88888 To charge a sealed-type (MF) bat-tery, a special (constant-voltage)battery charger is required. Us-ing a conventional batterycharger will damage the battery.If you do not have access to asealed-type (MF) battery charger,have a Yamaha dealer chargeyour battery.

EAUT1240

Replacing the fuse

1

ZAUM00**

1. Fuse

The fuse holder is located beside thebattery. Remove panel B to access thefuse. (See page 6-6.)

If the fuse is blown, replace it as fol-lows.

1. Turn the key to “OFF” and turn offall electrical circuits.

2. Remove the blown fuse, and theninstall a new fuse of the specifiedamperage.

Specified fuse:10 A

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ECA10640

cCDo not use a fuse of a higher amper-age rating than recommended toavoid causing extensive damage tothe electrical system and possibly afire.

3. Turn the key to “ON” and turn onthe electrical circuits to check if thedevices operate.

4. If the fuse immediately blows again,have a Yamaha dealer check theelectrical system.

EAUT1180

Engine oil and oil strainer

1

2

3

ZAUM00**

1. Level check window2. Maximum level3. Minimum level

The engine oil level should be checkedbefore each ride. In addition, the oil mustbe changed and the oil strainer cleanedat the intervals specified in the periodicmaintenance and lubrication chart.

To check the engine oil level1. Place the vehicle on the

centerstand.

NOTE:Make sure that the vehicle is positionedstraight up when checking the oil level.A slight tilt to the side can result in afalse reading.

2. Start the engine, warm it up for sev-eral minutes, and then turn it off.

3. Wait a few minutes until the oilsettles, and then check the oil levelthrough the check window locatedat the bottom-left side of the crank-case.

NOTE:The engine oil should be between theminimum and maximum level marks.

4. If the engine oil is below the mini-mum level mark, add sufficient oilof the recommended type to raiseit to the correct level.

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To change the engine oil and cleanthe oil strainer

1

ZAUM00**

1. Oil filler cap

1. Start the engine, warm it up for sev-eral minutes, and then turn it off.

2. Place an oil pan under the engineto collect the used oil.

3. Remove panel A. (See page 6-6.)4. Remove the engine oil filler cap and

drain bolts to drain the oil from thecrankcase.

4 3 2 1

1

ZAUM00**

1. Drain bolt B2. O-ring3. Spring4. Strainer

6.Check the O-ring for damage and re-place it if necessary.

7. Install the oil strainer, spring, O-ringand engine oil drain bolts, and thentighten the drain bolts to the speci-fied torque.

Tightening torque:Engine oil drain bolt A:

23 Nm (2.3m • kgf, 16.6ft • lbf)Engine oil drain bolt B:

32 Nm (3.2m • kgf, 23.1ft • lbf)

1ZAUM00**

1. Drain bolt AECA10410

cCWhen removing the engine oil drainbolt, the O-ring, spring, and oilstrainer will fall out. Take care not tolose these parts.

5. Clean the oil strainer with solvent,and then check it for damage andreplace it if necessary.

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NOTE:Make sure that the O-ring is properlyseated.

8. Add the specified amount of therecommended engine oil, and theninstall and tighten the engine oil fillercap.

Recommended engine oil:See page 8-1.

Oil change quantity:1.0 L (1.09 US qt) (0.92 Imp.qt)

ECA11670

cC88888 Do not use oils with a diesel

specification of “CD” or oils of ahigher quality than specified. Inaddition, do not use oils labeled“ENERGY CONSERVING II” orhigher.

88888 Be sure no foreign material en-ters the crankcase.

9. Start the engine, and then let it idlefor several minutes while checkingit for oil leakage. If oil is leaking,immediately turn the engine off andcheck for the cause.

10. Turn the engine off, and then checkthe oil level and correct it if neces-sary.

11. Install the panel.

EAU25860

TroubleshootingAlthough Yamaha scooters receive athorough inspection before shipmentfrom the factory, trouble may occur dur-ing operation. Any problem in the fuel,compression, or ignition systems, forexample, can cause poor starting andloss of power.The following troubleshooting chart rep-resents a quick and easy procedure forchecking these vital systems yourself.However, should your scooter require anyrepair, take it to a Yamaha dealer, whoseskilled technicians have the necessarytools, experience, and know-how to ser-vice the scooter properly.Use only genuine Yamaha replacementparts. Imitation parts may look likeYamaha parts, but they are often infe-rior, have a shorter service life and canlead to expensive repair bills.

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EAU25901

Troubleshooting chartEWA10840

wKeep away open flames and do not smoke while checking or working on the fuel system.

Check the fuel level inthe fuel tank.

1. FuelThere is enough fuel.

There is no fuel.

Check the compression.

Supply fuel. The engine does not start. Check the compression.

Operate the electric starter.

2. CompressionThere is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealercheck the vehicle.

Remove the spark plugand check the electrodes.

3. Ignition Wipe off with a dry cloth and correct thespark plug gap, or replace the spark plug.

Have a Yamaha dealer check the vehicle.

The engine does not start.Have a Yamaha dealercheck the vehicle.

The engine does not start.Check the battery.

Operate the electric starter.

4. BatteryThe engine turns over quickly.

The engine turns over slowly.

The battery is good.

Check the battery lead connections,and charge the battery if necessary.

Dry

WetOpen the throttle halfway and operatethe electric starter.

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SCOOTER CARE AND STORAGE

EAU26090

CareWhile the open design of a scooter re-veals the attractiveness of the technol-ogy, it also makes it more vulnerable.Rust and corrosion can develop even ifhigh-quality components are used. Arusty exhaust pipe may go unnoticed ona car, however, it detracts from the over-all appearance of a scooter. Frequent andproper care does not only comply withthe terms of the warranty, but it will alsokeep your scooter looking good, extendits life and optimize its performance.

Before cleaning1. Cover the muffler outlet with a plas-

tic bag after the engine has cooleddown.

2. Make sure that all caps and cov-ers as well as all electrical couplersand connectors, including the sparkplug cap, are tightly installed.

3. Remove extremely stubborn dirt,like oil burnt onto the crankcase,with a degreasing agent and abrush, but never apply such prod-ucts onto seals, gaskets and wheelaxles. Always rinse the dirt anddegreaser off with water.

CleaningECA10780

cC88888 Avoid using strong acidic wheel

cleaners, especially on spokedwheels. If such products are usedon hard-to-remove dirt, do notleave the cleaner on the affectedarea any longer than instructed.Also, thoroughly rinse the areaoff with water, immediately dryit, and then apply a corrosionprotection spray.

88888 Improper cleaning can damagewindshields, cowlings, panelsand other plastic parts. Use onlya soft, clean cloth or sponge withmild detergent and water to cleanplastic.

88888 Do not use any harsh chemicalproducts on plastic parts. Be sureto avoid using cloths or spongeswhich have been in contact withstrong or abrasive cleaning prod-ucts, solvent or thinner, fuel(gasoline), rust removers or in-hibitors, brake fluid, antifreeze orelectrolyte.

88888 Do not use high-pressure wash-

ers or steam-jet cleaners sincethey cause water seepage anddeterioration in the following ar-eas: seals (of wheel andswingarm bearings, fork andbrakes), electric components(couplers, connectors, instru-ments, switches and lights),breather hoses and vents.

88888 For scooters equipped with awindshield: Do not use strongcleaners or hard sponges as theywill cause dulling or scratching.Some cleaning compounds forplastic may leave scratches onthe windshield. Test the producton a small hidden part of thewindshield to make sure that itdoes not leave any marks. If thewindshield is scratched, use aquality plastic polishing com-pound after washing.

After normal useRemove dirt with warm water, a milddetergent, and a soft, clean sponge, and


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then rinse thoroughly with clean water.Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insectswill come off more easily if the area iscovered with a wet cloth for a few min-utes before cleaning.

After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on theroads during winter are extremely corro-sive in combination with water, carry outthe following steps after each ride in therain, near the sea or on salt-sprayedroads.

NOTE:Salt sprayed on roads in the winter mayremain well into spring.

1. Clean the scooter with cold waterand a mild detergent after the en-gine has cooled down.

ECA10790

cCDo not use warm water since it in-creases the corrosive action of thesalt.

2. Apply a corrosion protection sprayon all metal, including chrome- andnickel-plated, surfaces to preventcorrosion.

After cleaning1. Dry the scooter with a chamois or

an absorbing cloth.2. Use a chrome polish to shine

chrome, aluminum and stainless-steel parts, including the exhaustsystem. (Even the thermally in-duced discoloring of stainless-steelexhaust systems can be removedthrough polishing.)

3. To prevent corrosion, it is recom-mended to apply a corrosion pro-tection spray on all metal, includ-ing chrome- and nickel-plated, sur-faces.

4. Use spray oil as a universal cleanerto remove any remaining dirt.

5. Touch up minor paint damagecaused by stones, etc.

6. Wax all painted surfaces.7. Let the scooter dry completely be-

fore storing or covering it.

EWA10940

w88888 Make sure that there is no oil or

wax on the brakes or tires. If nec-essary, clean the brake discs andbrake linings with a regular brakedisc cleaner or acetone, andwash the tires with warm waterand a mild detergent.

88888 Before operating the scooter testits braking performance and cor-nering behavior.

ECA10800

cC88888 Apply spray oil and wax spar-

ingly and make sure to wipe offany excess.

88888 Never apply oil or wax to any rub-ber and plastic parts, but treatthem with a suitable care prod-uct.

88888 Avoid using abrasive polishingcompounds as they will wearaway the paint.

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NOTE:Consult a Yamaha dealer for advice onwhat products to use.

EAU26300

StorageShort-termAlways store your scooter in a cool, dryplace and, if necessary, protect itagainst dust with a porous cover.

ECA10820

cC88888 Storing the scooter in a poorly

ventilated room or covering itwith a tarp, while it is still wet,will allow water and humidity toseep in and cause rust.

88888 To prevent corrosion, avoiddamp cellars, stables (because ofthe presence of ammonia) andareas where strong chemicals arestored.

Long-termBefore storing your scooter for severalmonths:

1. Follow all the instructions in the“Care” section of this chapter.

2. Drain the carburetor float chamberby loosening the drain bolt; this willprevent fuel deposits from building

up. Pour the drained fuel into thefuel tank.

3. Fill up the fuel tank and add fuelstabilizer (if available) to prevent thefuel tank from rusting and the fuelfrom deteriorating.

4. Perform the following steps to pro-tect the cylinder, piston rings, etc.from corrosion.a. Remove the spark plug cap and

spark plug.b. Pour a teaspoonful of engine oil

into the spark plug bore.c. Install the spark plug cap onto

the spark plug, and then placethe spark plug on the cylinderhead so that the electrodes aregrounded. (This will limit spark-ing during the next step.)

d. Turn the engine over severaltimes with the starter. (This willcoat the cylinder wall with oil.)

e. Remove the spark plug cap fromthe spark plug, and then installthe spark plug and the spark plugcap.

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EWA10950

wTo prevent damage or injury fromsparking, make sure to ground thespark plug electrodes while turningthe engine over.

5. Lubricate all control cables and thepivoting points of all levers andpedals as well as of the sidestand/centerstand.

6. Check and, if necessary, correctthe tire air pressure, and then liftthe scooter so that both of itswheels are off the ground. Alterna-tively, turn the wheels a little everymonth in order to prevent the tiresfrom becoming degraded in onespot.

7. Cover the muffler outlet with a plas-tic bag to prevent moisture from en-tering it.

8. Remove the battery and fully chargeit. Store it in a cool, dry place andcharge it once a month. Do not storethe battery in an excessively coldor warm place [less than 0 °C (30

°F) or more than 30 °C (90 °F)]. Formore information on storing thebattery, see page 6-23.

NOTE:Make any necessary repairs before stor-ing the scooter.

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SPECIFICATIONS

Dimensions:Overall length:

1,755 mm (69.1 in)Overall width:

699 mm (27.5 in)Overall height:

1,063 mm (41.8 in)Seat height:

759 mm (29.8 in)Wheel base:

1,230 mm (48.4 in)Ground clearance:

95 mm (3.8 in)Minimum turning radius:

1,800 mm (72 in)Weight:

with oil and full fuel tank:109 kg (240 lb)

Engine:Engine type

Air-cooled 4-stroke, SOHCCylinder arrangement:

Forward-inclined single cylinderDisplacement:

125 cm3

Bore Stroke51.5×60.0 mm (2.0×2.4 in)

Compression ratio:9.8:1

Starting system:Electric / kick starter

Lubrication system:Wet sump

Oil type or gradeEngine oil

Type

Recommended engine oil classificationAPI Service SE, SF type or higher

Final gear oilType

SAE 85 W 140Oil quantity

Engine oilPeriodic oil change

1.0 L (1.09 US qt, 0.92 lmp.qt)Total amount

1.2 L (1.31 US qt, 1.10 lmp.qt)Final gear case oil

Periodic oil change0.13 L

Total amount0.15 L

Air filterPaper type element

FuelType

Regular unleaded gasoline(91 or higher)Fuel tank capacity

4.5 L (1.18 US qt, 0.98 lmp.gal)Carburetor

Type×quantityBS26×1

ManufacturerMikuni

Spark plugType / Manufacturer

CR7E / NGKGap

0.7 ~ 0.8 mm (0.028 ~ 0.032 in)Transmission

Primary reduction systemHelical gear

Primary reduction ratio40/15(2.666)

Secondary reduction systemSpur gear

Secondary reduction ratio38/13(2.923)

Transmission typeSingle speed automatic(V-belt type)

OperationCentrifugal automatic type

ChassisFrame type

Steel tube underboneCaster angle

32°Trail

75 mm

SPECIFICATIONS

-20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚

SAE 10W-30

SAE 10W-40

SAE 20W-40

SAE 20W-50

ZAUM00**

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SPECIFICATIONS

Front tireType

TubelessSize

3.50-10 51JManufacturer

Cheng shinRear tire

TypeTubeless

Size3.50-10 51J

ManufacturerCheng shin

Maximum load*144 kg (317 lb)

Tire air pressure(Cold tire)Up to 90 kg (198 lb) load*Front

150 kPa(1.50 kg / cm2, 22 psi)Rear

200 kPa(2.00 kg / cm2, 29 psi)90 kg load ~ maximum load*Front

150 kPa(1.50 kg / cm2, 22 psi)Rear

225 kPa(2.25 kg / cm2,32 psi)*Load is total weight of cargo, rider and acces-sories.Front wheel

TypeCast

SizeJ10×MT 2.5

Rear wheelType

CastSize

J10×MT 2.5Front brake

TypeSingle disc brake

OperationRight hand operation

FluidDOT 4

Rear brakeType

DrumOperation

Left hand operationFront suspension

TypeTelescopic fork

Rear suspensionType

Unit swingShock absorbers

FrontCoil spring / oil damper

RearCoil spring / oil damper

Wheel travelFront

59 mmRear

54 mm

Electrical systemIgnition system

C.D.I.Charging system

TypeC.D.I. magneto generator

Standard output14 V,120W / 5,000 r/min

BatteryType

GTX 7A-BSVoltage, capacity

12 V, 6 AHHeadlight type

BulbBulb voltage, wattage quantity

Headlight12 V, 60 / 65 W×1

Tail / brake light12 V, 8 / 27 W×1

Turn signal light12 V, 10 W×4

Meter light14 V, 3 W×1

Fuel meter light14 V, 3 W×1

High beam indicator light12 V, 3 W×1

Turn indicator light12 V, 1.7 W×1

Fuse10A 1

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CONSUMER INFORMATION

EAU26351

Identification numbersRecord the key identification number,vehicle identification number and modellabel information in the spaces providedbelow for assistance when orderingspare parts from a Yamaha dealer or forreference in case the vehicle is stolen.

KEY IDENTIFICATION NUMBER:

VEHICLE IDENTIFICATION NUMBER:

MODEL LABEL INFORMATION:

EAU26390

Key identification number

1

ZAUM00**

1. Key identification number

The key identification number isstamped into the key.Record this number in the space pro-vided and use it for reference when or-dering a new key.

EAU26410

Vehicle identification number

1

ZAUM00**

1. Vehicle identification number

The vehicle identification number isstamped into the frame.

NOTE:The vehicle identification number is usedto identify your motorcycle and may beused to register your motorcycle withthe licensing authority in your area.


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EAU26460

Model label

1

ZAUM00**

1. Model label

The model label is affixed to the loca-tion shown. Record the information onthis label in the space provided. Thisinformation will be needed when order-ing spare parts from a Yamaha dealer.

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EAU26550

Reporting safety defectsIf you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immedi-ately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation,U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in agroup of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individualproblems between you, your dealer, or Yamaha Motor Corporation, U.S.A.

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other informationabout motor vehicle safety from the Hotline.

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EAU26560

Motorcycle noise regulationTAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person otherthan for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any newvehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the useof the vehicle after such device or element of design has been removed or rendered inoperative by any person.

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”.

These acts include tampering with the following systems; i.e., modification, removal, etc.

Exhaust systemMufflerExhaust pipeSilencer

Intake systemAir cleaner caseAir cleaner elementIntake duct

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EAU26661

YAMAHA MOTOR CORPORATION, U.S.A.STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY

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EAU26750

YAMAHA EXTENDED SERVICE (Y.E.S.)

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INDEX

AAcceleration and deceleration .................. 5-2Adjusting the brake lever free play ........ 6-21Adjusting the carburetor ......................... 6-19Adjusting the rear brake lever free play 6-21Adjusting the throttle cable free play ...... 6-19Air filter and V-belt case air filterelements .................................................. 6-8

BBattery ..................................................... 6-22Braking ...................................................... 5-3

CCONSUMER INFORMATION ................. 9-1Care .......................................................... 7-1Carrier ....................................................... 3-8Cast wheels ............................................ 6-21Catalytic converter ................................... 3-5Changing the brake fluid ......................... 6-13Checking and lubricating the cables ...... 6-14Checking and lubricating the centerstand andsidestand ............................................... 6-15

Checking and lubricating the throttle grip andcable ...................................................... 6-14

Checking the brake fluid level ................ 6-13Checking the front brake pads and rear brakeshoes .................................................... 6-12

Checking the front fork ........................... 6-15Checking the spark plug .......................... 6-7Checking the steering ............................ 6-16Controls and instruments ......................... 2-3

DDESCRIPTION ......................................... 2-1

EEngine break-in ......................................... 5-3Engine oil and oil strainer ........................ 6-24

FFinal transmission oil .............................. 6-17Front brake lever ...................................... 3-3Fuel ........................................................... 3-5Fuel gauge ................................................ 3-3Fuel tank cap ............................................ 3-4Further safe-riding points ......................... 1-5

GGeneral maintenance and lubricationchart ........................................................ 6-3

HHandlebar switches .................................. 3-2Helmet holder ............................................ 3-6

IINSTRUMENT AND CONTROLFUNCTIONS .......................................... 3-1

Identification numbers .............................. 9-1Ignition circuit cut-off system ................... 3-9Indicator lights ........................................... 3-2

KKickstarter ................................................ 3-6

LLeft view .................................................... 2-1Location of important labels ..................... 1-6Lubricating the front and rear brakelevers .................................................... 6-14

Luggage hook ........................................... 3-8M

Main switch/steering lock ......................... 3-1Motorcycle noise regulation ..................... 9-4

OOPERATION AND IMPORTANT RIDINGPOINTS ................................................... 5-1

Owner’s tool kit ......................................... 6-1

PPERIODIC MAINTENANCE .................... 6-1PERIODIC MAINTENANCE AND MINORREPAIR ................................................... 6-1

PRE-OPERATION CHECKS ................... 4-1Parking ...................................................... 5-4Periodic maintenance chart for the emissioncontrol system ........................................ 6-2

Pre-operation check list ........................... 4-2R

Rear brake lever ....................................... 3-4Removing and installing panels ................ 6-6Replacing a turn signal light bulb ............ 6-11Replacing the fuse .................................. 6-23Replacing the headlight bulb .................. 6-16Replacing the tail/brake light bulb ........... 6-11Reporting safety defects .......................... 9-3Right view ................................................. 2-2

SSAFETY INFORMATION ......................... 1-1SCOOTER CARE AND STORAGE ........ 7-1SPECIFICATIONS .................................... 8-1Seat ........................................................... 3-6Sidestand .................................................. 3-8Speedometer unit ..................................... 3-3Starting a cold engine ............................... 5-1Starting off ................................................. 5-2Storage ...................................................... 7-3Storage compartment ............................... 3-7

TTires ........................................................ 6-19Troubleshooting ...................................... 6-26Troubleshooting chart ............................. 6-27

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INDEX

YYAMAHA EXTENDED SERVICE (Y.E.S.) 9-7YAMAHA MOTOR CORPORATION, U.S.ASTREET AND ENDURO MOTORCYCLELIMITED WARRANTY ............................ 9-5

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INDEX

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INDEX

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PRINTED IN TAIWAN2003.11-0.8 1 !

(E)

YAMAHA MOTOR TAIWAN CO., LTD

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Documents

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