Yamaha Automobile 5RU2819913 User Manual

OWNER’S MANUAL

YP400X

LIT-11626-21-34

5RU-28199-13

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INTRODUCTION

EAU10090

Congratulations on your purchase of the Yamaha YP400X. This model is the result of Yamaha’s vast experience in the pro-

duction of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reli-

ability 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 have

any 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 the

date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of the

scooter. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the rec-

ommended maintenance schedules and operating instructions contained within this manual.

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IMPORTANT MANUAL INFORMATION

EAU35821

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT!YOUR SAFETY IS

INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the

scooter operator, a bystander, or a person inspecting or repairing the scooter.

WARNING

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to

the scooter.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

NOTE:

G This manual should be considered a permanent part of this scooter and should remain with it even if the scooter is sub-

sequently sold.

^GYamaha 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.

EWA12580

WARNING

PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY

AND COMPLETELY BEFORE OPERATING THIS SCOOTER. DO NOT ATTEMPT TO OPERATE THIS SCOOTER UN-

TIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL

YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CARE-

FUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPA-

BILITIES AND THE RELIABILITY OF THIS SCOOTER.

*Product and specifications are subject to change without notice.

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IMPORTANT MANUAL INFORMATION

EAU10192

AFFIX DEALER

LABEL HERE

YP400X

OWNER’S MANUAL

1st edition, April 2007

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in Japan.

P/N LIT-11626-21-34

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TABLE OF CONTENTS

SAFETY INFORMATION ...................1-1

Further safe-riding points .................1-4

Location of important labels .............1-6

PRE-OPERATION CHECKS ..............4-1

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

Checking the throttle cable free

play ............................................ 6-23

Valve clearance ............................ 6-23

Tires .............................................. 6-23

Cast wheels .................................. 6-25

Accessories and replacement

OPERATION AND IMPORTANT

DESCRIPTION ...................................2-1

Left view ...........................................2-1

Right view.........................................2-2

Controls and instruments..................2-3

RIDING POINTS..................................5-1

Starting the engine ..........................5-1

Starting off .......................................5-2

Acceleration and deceleration .........5-2

Braking ............................................5-2

Engine break-in ...............................5-3

Parking ............................................5-4

parts ........................................... 6-26

Front and rear brake lever free

play ............................................ 6-26

Adjusting the rear brake lock lever

cable .......................................... 6-27

Checking the front and rear brake

pads ........................................... 6-28

Checking the brake fluid level ....... 6-28

Changing the brake fluid ............... 6-29

Checking and lubricating the

cables ........................................ 6-30

Checking and lubricating the throttle

grip and cable ............................ 6-30

Lubricating the front and rear brake

levers ......................................... 6-30

Checking and lubricating the

centerstand and sidestand ........ 6-31

Checking the front fork .................. 6-31

Checking the steering ................... 6-32

Checking the wheel bearings ........ 6-33

Battery ........................................... 6-33

Replacing the fuses ...................... 6-34

Replacing a headlight bulb ........... 6-36

Tail/brake light ............................... 6-36

INSTRUMENT AND CONTROL

FUNCTIONS........................................3-1

Main switch/steering lock .................3-1

Indicator and warning lights .............3-2

Speedometer ...................................3-2

Tachometer .....................................3-3

Multi-function display .......................3-3

Handlebar switches .........................3-7

Front brake lever .............................3-8

Rear brake lever ..............................3-8

Rear brake lock lever .......................3-8

Fuel tank cap ...................................3-9

Fuel ................................................3-10

Catalytic converter .........................3-11

Seats .............................................3-11

Adjusting the rider seat ..................3-13

Storage compartments ..................3-13

Adjusting the shock absorber

PERIODIC MAINTENANCE AND

MINOR REPAIR..................................6-1

PERIODIC MAINTENANCE ............6-1

Owner’s tool kit ................................6-2

Periodic maintenance chart for the

emission control system ..............6-3

General maintenance and lubrication

chart .............................................6-4

Removing and installing cowlings

and panels ...................................6-8

Checking the spark plug ................6-12

Canister .........................................6-14

Engine oil and oil filter element .....6-14

Final transmission oil .....................6-17

Coolant ..........................................6-18

Air filter elements and check hoses

and V-belt case air filter

assemblies .................................3-15

Sidestand .......................................3-16

Ignition circuit cut-off system .........3-16

element ......................................6-20

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TABLE OF CONTENTS

Replacing a front turn signal light

bulb ............................................6-36

Replacing a rear turn signal light

bulb ............................................6-37

Replacing the license plate light

bulb ............................................6-38

Troubleshooting .............................6-39

Troubleshooting charts ..................6-40

SCOOTER CARE AND STORAGE ....7-1

Matte color caution ..........................7-1

Care .................................................7-1

Storage ............................................7-3

SPECIFICATIONS ..............................8-1

CONSUMER INFORMATION..............9-1

Identification numbers .....................9-1

Reporting safety defects ..................9-3

Scooter noise regulation ..................9-4

Maintenance record .........................9-5

YAMAHA MOTOR CORPORATION,

U.S.A. STREET AND ENDURO

MOTORCYCLE LIMITED

WARRANTY .................................9-7

YAMAHA EXTENDED SERVICE

(Y.E.S.) ........................................9-9

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SAFETY INFORMATION

EAU10261

TIONS.

^GMany accidents involve inexperi-

enced operators. In fact, many op-

erators who have been involved in

accidents do not even have a cur-

rent driver’s license.

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 OPERA-

TOR. EVERY OPERATOR SHOULD

KNOW THE FOLLOWING REQUIRE-

MENTS BEFORE RIDING THIS

SCOOTER.

Safe riding

G Always

make

pre-operation

checks. Careful checks may help

prevent an accident.

Make sure that you are qualified

and that you only lend your

scooter to other qualified opera-

tors.

G This scooter is designed to carry

the operator and passenger.

^GThe failure of motorists to detect

and recognize scooters in traffic is

the predominating cause of auto-

mobile/scooter accidents. Many

accidents have been caused by an

automobile driver who did not see

the scooter. Making yourself con-

spicuous appears to be very effec-

tive in reducing the chance of this

type of accident.

Know your skills and limits.

Staying within your limits may

help you to avoid an accident.

We recommend that you prac-

tice riding your scooter where

there is no traffic until you have

become thoroughly familiar with

the scooter and all of its con-

trols.

HE OR SHE SHOULD:

G OBTAIN THOROUGH INSTRUC-

TIONS FROM A COMPETENT

SOURCE ON ALL ASPECTS OF

SCOOTER OPERATION.

G OBSERVE THE WARNINGS

AND MAINTENANCE REQUIRE-

MENTS IN THE OWNER’S MAN-

UAL.

G OBTAIN QUALIFIED TRAINING

IN SAFE AND PROPER RIDING

TECHNIQUES.

G OBTAIN PROFESSIONAL TECH-

NICAL SERVICE AS INDICATED

BY THE OWNER’S MANUAL

AND/OR WHEN MADE NECES-

SARY BY MECHANICAL CONDI-

G Therefore:

G Many accidents have been caused

by error of the scooter operator. A

typical error made by the operator

is veering wide on a turn due to

EXCESSIVE SPEED or undercor-

nering (insufficient lean angle for

the speed).

Wear a brightly colored jacket.

Use extra caution when ap-

proaching and passing through

intersections, since intersec-

tions 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.

Always obey the speed limit and

never travel faster than warrant-

ed by road and traffic conditions.

1-1

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SAFETY INFORMATION

Always signal before turning or ries. The use of a safety helmet is the approved by Yamaha, or the removal of

changing lanes. Make sure that single most critical factor in the preven- original equipment, may render the

other motorists can see you.

tion or reduction of head injuries.

scooter unsafe for use and may cause

G The posture of the operator and

passenger is important for proper

control.

G Always wear an approved helmet. severe personal injury. Modifications

G Wear a face shield or goggles. may also make your scooter illegal to

Wind in your unprotected eyes use.

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.

could contribute to an impairment

of vision which could delay seeing Loading and accessories

a hazard.

Adding accessories or cargo to your

G The use of a jacket, substantial scooter can adversely affect stability

shoes, trousers, gloves, etc., is ef- and handling if the weight distribution of

fective in preventing or reducing the scooter is changed. To avoid the

abrasions or lacerations.

possibility of an accident, use extreme

^GNever wear loose-fitting clothes, caution when adding cargo or accesso-

otherwise they could catch on the ries to your scooter. Use extra care

control levers or wheels and cause when riding a scooter that has added

injury or an accident.

cargo or accessories. Here are some

^GNever touch the engine or exhaust general guidelines to follow if loading

system during or after operation. cargo or adding accessories to your

They become very hot and can scooter:

^GNever ride under the influence of

alcohol or other drugs.

cause burns. Always wear protec-

G This scooter is designed for

on-road use only. It is not suitable

for off-road use.

tive clothing that covers your legs, Loading

ankles, and feet.

The total weight of the operator, pas-

G Passengers should also observe senger, accessories and cargo must

the above precautions.

not exceed the maximum load limit.

Protective apparel

The majority of fatalities from scooter Modifications

accidents are the result of head inju- Modifications made to this scooter not

Maximum load:

196 kg (432 lb)

1-2

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SAFETY INFORMATION

When loading within this weight limit, and use of non-Yamaha accessories.

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 dis-

place the operator from his or

her normal riding position. This

improper position limits the free-

dom of movement of the opera-

tor and may limit control ability,

therefore, such accessories are

not recommended.

keep the following in mind:

Use extreme caution when selecting

^GCargo and accessory weight and installing any accessories.

should be kept as low and close to Keep the following guidelines in mind,

the scooter as possible. Make sure as well as those provided under “Load-

to distribute the weight as evenly ing” when mounting accessories.

as possible on both sides of the

scooter to minimize imbalance or

instability.

G Never install accessories or carry

cargo that would impair the perfor-

mance of your scooter. Carefully

inspect the accessory before using

it to make sure that it does not in

any way reduce ground clearance

or cornering clearance, limit sus-

pension travel, steering travel or

control operation, or obscure lights

or reflectors.

G Shifting weights can create a sud-

den imbalance. Make sure that ac-

cessories 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.

G Use caution when adding electri-

cal accessories. If electrical acces-

sories 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.

Accessories fitted to the handle-

bar or the front fork area can

create instability due to improper

weight distribution or aerody-

namic changes. If accessories

are added to the handlebar or

front fork area, they must be as

Accessories

Genuine Yamaha accessories have

been specifically designed for use on

this scooter. Since Yamaha cannot test

all other accessories that may be avail-

able, you must personally be responsi-

ble for the proper selection, installation

lightweight as possible and Gasoline and exhaust gas

should be kept to a minimum.

Bulky or large accessories may

seriously affect the stability of

the scooter due to aerodynamic

G GASOLINE IS HIGHLY FLAMMA-

BLE:

Always turn the engine off when

refueling.

1-3

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SAFETY INFORMATION

EAU10371

Further safe-riding points

^GBe sure to signal clearly when

making turns.

G 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.

^GSlow down as you approach a cor-

ner or turn. Once you have com-

pleted a turn, accelerate slowly.

^GBe careful when passing parked

cars. A driver might not see you

and open a door in your path.

G Railroad crossings, streetcar rails,

iron plates on road construction

sites, and manhole covers be-

come extremely slippery when

wet. Slow down and cross them

with caution. Keep the scooter up-

right, otherwise it could slide out

from under you.

Take care not to spill any gaso-

line on the engine or exhaust

system when refueling.

Never refuel while smoking or in

the vicinity of an open flame.

sene heater, or near an open

flame), otherwise it could catch

fire.

G If you should swallow any gaso-

line, inhale a lot of gasoline vapor,

or allow gasoline to get into your

eyes, see your doctor immediate-

ly. If any gasoline spills on your

skin or clothing, immediately wash

the affected area with soap and

water and change your clothes.

^GNever start the engine or let it run

for any length of time in a closed

area. The exhaust fumes are poi-

sonous and may cause loss of

consciousness and death within a

short time. Always operate your

scooter in an area that has ade-

quate ventilation.

^GAlways 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 pedes-

trians or children are not likely to

touch these hot areas.

^GThe brake pads could get wet

when you wash the scooter. After

washing the scooter, check the

brakes before riding.

^GAlways wear a helmet, gloves,

trousers (tapered around the cuff

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 kero-

1-4

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SAFETY INFORMATION

and ankle so they do not flap), and

a bright colored jacket.

^GDo not carry too much luggage on

the scooter. An overloaded scoot-

er is unstable.

1-5

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SAFETY INFORMATION

EAU10381

Location of important labels

Please read the following important labels carefully before operating this vehicle.

2 3 4 5 6

1-6

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SAFETY INFORMATION

CAUTION

Cleaning with alkaline or acid cleaner,

gasoline or solvent will damage windshield.

Use neutral detergent.

—

3JJ 2835Y A0

WARNING

5RU-21668-00

BEFORE YOU OPERATE THIS VEHICLE, READ

THE OWNER’S MANUAL AND ALL LABELS.

ALWAYS WEAR AN APPROVED MOTORCYCLE

HELMET, eye protection, and protective clothing.

5GK-2118K-00

WARNING

Improper loading can cause loss of control.

Read owner’s manual for proper loading.

—

3JJ 28446 A1

LOAD LIMIT

2 kg {4 lbs}

5RU-24877-A0

LOAD LIMIT

5 kg {11 lbs}

3LD-24877-A0

1-7

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SAFETY INFORMATION

5RU 21686 00

1-8

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DESCRIPTION

EAU10410

Left view

1. Headlight (page 6-36)

2. Fuel tank cap (page 3-9)

9. Air ﬁlter element (left) (page 6-20)

10. Engine oil ﬁlter element (page 6-14)

11. Sidestand (page 3-16, 6-31)

3. Rear storage compartment (page 3-13)

4. V-belt case air ﬁlter element (page 6-20)

5. Owner’s tool kit (page 6-2)

6. Fuses (page 6-34)

7. Battery (page 6-33)

8. Shock absorber assembly spring preload adjusting ring (page 3-15)

2-1

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DESCRIPTION

EAU10420

Right view

1. Grab bar (page 5-2)

2. Passenger seat (page 3-11)

3. Rider seat (page 3-11)

4. Coolant reservoir (page 6-18)

5. Radiator

6. Centerstand (page 6-31)

7. Air ﬁlter element (right) (page 6-20)

8. Shock absorber assembly spring preload adjusting ring (page 3-15)

2-2

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DESCRIPTION

EAU10430

Controls and instruments

1. Rear brake lever (page 3-8)

2. Left handlebar switches (page 3-7)

3. Rear brake lock lever (page 3-8)

4. Speedometer (page 3-2)

9. Throttle grip (page 6-23)

10. Front storage compartment B (page 3-13)

11. Main switch/steering lock (page 3-1)

12. Front storage compartment A (page 3-13)

5. Multi-function display (page 3-3)

6. Tachometer (page 3-3)

7. Right handlebar switches (page 3-7)

8. Front brake lever (page 3-8)

2-3

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INSTRUMENT AND CONTROL FUNCTIONS

EAU10460

sidestand is moved down.

loss of control or an accident. Make

sure that the vehicle is stopped be-

fore turning the key to “OFF” or

“LOCK”.

Main switch/steering lock

EAU10660

OFF

All electrical systems are off. The key

can be removed.

EAU10680

LOCK

The steering is locked, and all electrical

systems are off. The key can be re-

moved.

The main switch/steering lock controls

the ignition and lighting systems, and is

used to lock the steering. The various

positions are described below.

To lock the steering

1. 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.

EAU36070

3. Remove the key.

All electrical circuits are supplied with

power; the meter lighting, taillight, li-

cense plate light and position lights

come on, and the engine can be start-

ed. The key cannot be removed.

To unlock the steering

Push the key in, and then turn it to

“OFF” while still pushing it.

EWA10060

NOTE:

WARNING

The headlights come on automatically

when the engine is started and stay on

until the key is turned to “OFF” or the

Never turn the key to “OFF” or

“LOCK” while the vehicle is moving,

otherwise the electrical systems will

be switched off, which may result in

3-1

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INSTRUMENT AND CONTROL FUNCTIONS

EAU11003

EAU11480

EAU11601

Engine trouble warning light “

”

Indicator and warning lights

Speedometer

This warning light comes on when an

electrical circuit monitoring the engine

is defective. When this occurs, have a

Yamaha dealer check the self-diagno-

sis system.

2 3

The electrical circuit of the warning light

can be checked by turning the key to

“ON”. If the warning light does not come

on for a few seconds, then go off, have

a Yamaha dealer check the electrical

circuit.

1. Speedometer

1. Turn signal indicator lights “

2. High beam indicator light “

3. Engine trouble warning light “

” and “

”

The speedometer shows the riding

speed.

”

When the key is turned to “ON”, the

speedometer needle will sweep once

across the speed range and then return

to zero in order to test the electrical cir-

cuit.

EAU11030

Turn signal indicator lights “ ” and

“

”

The corresponding indicator light flash-

es when the turn signal switch is

pushed to the left or right.

EAU11080

High beam indicator light “

”

This indicator light comes on when the

high beam of the headlight is switched

on.

3-2

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INSTRUMENT AND CONTROL FUNCTIONS

EAU11872

EAU36105

Tachometer

Multi-function display

EWA12311

WARNING

Be sure to stop the vehicle before

making any setting changes to the

multi-function display.

1. V-belt replacement indicator “V-BELT”

2. Fuel level warning indicator “

3. Coolant temperature warning indicator

”

1. Tachometer

2. Tachometer red zone

“

”

4. Oil change indicator “OIL”

The electric tachometer allows the rider

to monitor the engine speed and keep it

within the ideal power range.

When the key is turned to “ON”, the ta-

chometer needle will sweep once

across the r/min range and then return

to zero r/min in order to test the electri-

The multi-function display is equipped

with the following:

^Ga fuel meter

G a coolant temperature meter

^Gan odometer (which shows the to-

tal distance traveled)

^Gtwo tripmeters (which show the

distance traveled since they were

last set to zero)

G a fuel reserve tripmeter (which

shows the distance traveled since

the bottom segment of the fuel

meter and fuel level warning indi-

1. Clock/ambient temperature display

2. Coolant temperature meter

3. Fuel meter

4. Odometer/tripmeters

5. “SELECT” button

cal circuit.

6. “RESET” button

ECA10031

CAUTION:

Do not operate the engine in the ta-

chometer red zone.

Red zone: 8250 r/min and above

3-3

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INSTRUMENT AND CONTROL FUNCTIONS

cator started flashing)

G a self-diagnosis device

^Ga clock

G an ambient temperature display

G an oil change indicator

^Ga V-belt replacement indicator

tor will start flashing, and the display will the fuel reserve tripmeter manually, it

automatically change to the fuel re- will reset itself automatically and the

serve tripmeter mode “TRIP F” and display will return to the prior mode af-

start counting the distance traveled ter refueling and traveling 5 km (3 mi).

from that point. In that case, pushing

the “SELECT” button switches the dis-

play between the various tripmeter and

odometer modes in the following order:

NOTE:

The display cannot be changed back to

“TRIP F” after pushing the “RESET”

button.

NOTE:

^GBe sure to turn the key to “ON” be-

fore using the “SELECT” and “RE-

SET” buttons.

^GWhen the key is turned to “ON”, all

of the display segments of the

multi-function display will appear

one after the other and then disap-

pear, in order to test the electrical

circuit.

TRIP F → TRIP (top) → TRIP (bottom)

→ ODO → TRIP F

Fuel meter

With the key in the “ON” position, the

fuel meter indicates the amount of fuel

in the fuel tank. The display segments

of the fuel meter disappear towards “E”

(Empty) as the fuel level decreases.

When the fuel level reaches the bottom

segment near “E”, the fuel level warn-

Odometer and tripmeter modes

Pushing the “SELECT” button switches

the display between the odometer

mode “ODO” and the tripmeter modes

“TRIP” in the following order:

ODO → TRIP (top) → TRIP (bottom) →

ODO

When approximately 2.8 L (0.74 US

gal) (0.62 Imp.gal) of fuel remains in the

fuel tank, the bottom segment of the

fuel meter and fuel level warning indica-

ing indicator and the bottom segment

will flash. Refuel as soon as possible.

1. Fuel reserve tripmeter

Coolant temperature meter

To reset a tripmeter, select it by push-

ing the “SELECT” button until “TRIP” or

“TRIP F” begins flashing (“TRIP” or

“TRIP F” will only flash for five sec-

onds). While “TRIP” or “TRIP F” is

flashing, push the “RESET” button for

at least one second. If you do not reset

With the key in the “ON” position, the

coolant temperature meter indicates

the temperature of the coolant. The

coolant temperature varies with chang-

es in the weather and engine load. If

the top segment and coolant tempera-

ture warning indicator flash, stop the

3-4

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INSTRUMENT AND CONTROL FUNCTIONS

vehicle and let the engine cool. (See been reached), the indicator must be procedure.

page 6-40.)

reset after the oil change for the next

periodic oil change to be indicated at

the correct time. (See page 6-14.)

The electrical circuit of the indicator can

be checked according to the following

procedure.

1. Turn the key to “ON” and make

sure that the engine stop switch is

set to “ ”.

2. If the indicator does not come on,

have a Yamaha dealer check the

electrical circuit.

1. Set the engine stop switch to “

and turn the key to “ON”.

2. Check that the indicator comes on This model is equipped with a self-diag-

for a few seconds and then goes nosis device for various electrical cir-

off.

3. If the indicator does not come on, If any of those circuits are defective, the

have a Yamaha dealer check the multi-function display will indicate a

”

Self-diagnosis device

cuits.

ECA10020

CAUTION:

Do not operate the engine if it is

overheated.

electrical circuit.

two-digit error code.

If the multi-function display indicates

such an error code, note the code num-

ber, and then have a Yamaha dealer

check the vehicle.

NOTE:

The oil change indicator may flash

when the engine is revved with the

scooter on the centerstand, but this

does not indicate a malfunction.

Oil change indicator “OIL”

This indicator flashes at the initial

1000 km (600 mi), then at 5000 km

(3000 mi) and every 5000 km (3000

mi) thereafter to indicate that the en-

gine oil should be changed.

After changing the engine oil, reset the

oil change indicator. (See page 6-14.)

If the engine oil is changed before the

oil change indicator comes on (i.e. be-

fore the periodic oil change interval has

V-belt replacement indicator

“V-BELT”

This indicator flashes every 20000 km

(12500 mi) when the V-belt needs to be

replaced.

The electrical circuit of the indicator can

be checked according to the following

3-5

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INSTRUMENT AND CONTROL FUNCTIONS

the minute digits will start flashing.

4. Push the “RESET” button to set

the minutes.

5. Push the “SELECT” button and

then release it to start the clock.

Pushing the “SELECT” button for

at least two seconds switches the

will not be displayed.

G The accuracy of the temperature

reading may be affected when

riding slowly (approximately under

20 km/h (12.5 mi/h)) or when

stopped at traffic signals, railroad

crossings, etc.

clock display to the ambient tem-

perature display.

1. Error code display

Ambient temperature display

This display shows the ambient tem-

perature from –10 °C (14 °F) to 50 °C

(122 °F) in 1 °C or 1 °F increments. The

temperature displayed may vary from

the ambient temperature. Pushing the

“SELECT” button for at least two sec-

onds switches the ambient temperature

display to the clock display.

ECA11790

CAUTION:

If the multi-function display indi-

cates an error code, the vehicle

should be checked as soon as pos-

sible in order to avoid engine dam-

age.

NOTE:

Clock mode

To set the clock:

^GIf the ambient temperature falls be-

low –10 °C (14 °F), a lower tem-

perature than –10 °C (14 °F) will

not be displayed.

^GIf the ambient temperature climbs

above 50 °C (122 °F), a higher

temperature than 50 °C (122 °F)

1. Push the “SELECT” button and

“RESET” button together for at

least two seconds.

2. When the hour digits start flashing,

push the “RESET” button to set the

hours.

3. Push the “SELECT” button, and

3-6

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INSTRUMENT AND CONTROL FUNCTIONS

EAU12347

EAU12500

Right

Horn switch “

”

Handlebar switches

Press this switch to sound the horn.

Left

EAU12660

Engine stop switch “

”

Set this switch to “ ” before starting

the engine. Set this switch to “ ” to

stop the engine in case of an emergen-

cy, such as when the vehicle overturns

or when the throttle cable is stuck.

1. Engine stop switch “

”

EAU12720

2. Start switch “

”

Start switch “

”

With the sidestand up, push this switch

while applying the front or rear brake to

1. Dimmer switch “

”

EAU12400

Dimmer switch “

”

2. Turn signal switch “

”

crank the engine with the starter.

Set this switch to “ ” for the high

beam and to “ ” for the low beam.

3. Horn switch “

”

ECA10050

CAUTION:

See page 5-1 for starting instruc-

tions prior to starting the engine.

EAU12460

Turn signal switch “

”

To signal a right-hand turn, push this

switch to “ ”. To signal a left-hand

turn, push this switch to “ ”. When re-

leased, the switch returns to the center

position. To cancel the turn signal

lights, push the switch in after it has re-

turned to the center position.

3-7

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INSTRUMENT AND CONTROL FUNCTIONS

EAU12900

EAU12950

EAU12962

Front brake lever

Rear brake lever

Rear brake lock lever

1. Front brake lever

1. Rear brake lever

1. Rear brake lock lever

The front brake lever is located on the The rear brake lever is located on the This vehicle is equipped with a rear

right handlebar grip. To apply the front left handlebar grip. To apply the rear brake lock lever to prevent the rear

brake, pull this lever toward the handle- brake, pull this lever toward the handle- wheel from moving while stopped at

bar grip.

traffic signals, railroad crossings, etc.

To lock the rear wheel

Push the rear brake lock lever to the left

until it snaps into place.

To unlock the rear wheel

Push the rear brake lock lever back to

the original position.

NOTE:

^GBe sure to check that the rear

wheel does not move when the

3-8

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INSTRUMENT AND CONTROL FUNCTIONS

EAU13162

rear brake lock lever is applied.

G To provide secure locking of the

rear wheel, apply the rear brake le-

ver first before moving the rear

brake lock lever to the left.

Fuel tank cap

To open the fuel tank cap

1. Open the lid by sliding the lever

forward, and then pull the lever up.

EWA12361

WARNING

Never move the rear brake lock lever

to the left while the vehicle is mov-

ing, otherwise loss of control or an

accident may result. Make sure that

the vehicle is stopped before mov-

ing the rear brake lock lever to the

left.

1. Fuel tank cap

To install the fuel tank cap

1. Align the match marks, insert the

fuel tank cap into the tank opening,

and then push down on the cap.

1. Lid

2. Opening lever

2. Insert the key into the lock and turn

it clockwise. The lock will be re-

leased and the fuel tank cap can

be removed.

1. Match marks

2. Turn the key counterclockwise to

the original position, and then re-

3-9

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INSTRUMENT AND CONTROL FUNCTIONS

EAU13211

move it.

3. Close the lid.

fuel may deteriorate painted surfac-

es or plastic parts.

Fuel

EWA11120

WARNING

EAU36080

Be sure that the fuel tank cap is

properly installed and locked before

riding the scooter.

Recommended fuel

UNLEADED GASOLINE ONLY

Fuel tank capacity:

14.0 L (3.70 US gal) (3.08 Imp.gal)

ECA11400

CAUTION:

1. Fuel tank ﬁller tube

2. Fuel level

Use only unleaded gasoline. The use

of leaded gasoline will cause severe

damage to internal engine parts,

such as the valves and piston rings,

as well as to the exhaust system.

Make sure that there is sufficient fuel in

the tank. Fill the fuel tank to the bottom

of the filler tube as shown.

EWA10880

Your Yamaha engine has been de-

signed to use regular unleaded gaso-

line with a pump octane number

[(R+M)/2] of 86 or higher, or a research

octane number of 91 or higher. If

knocking (or pinging) occurs, use a

gasoline of a different brand or premi-

um unleaded fuel. Use of unleaded fuel

will extend spark plug life and reduce

maintenance costs.

WARNING

^GDo not overfill the fuel tank, oth-

erwise it may overflow when the

fuel warms up and expands.

^GAvoid spilling fuel on the hot en-

gine.

ECA10070

CAUTION:

Immediately wipe off spilled fuel

with a clean, dry, soft cloth, since

3-10

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INSTRUMENT AND CONTROL FUNCTIONS

EAU13431

EAU34140

Gasohol

Catalytic converter

Seats

There are two types of gasohol: gaso-

hol containing ethanol and that contain-

ing methanol. Gasohol containing

ethanol can be used if the ethanol con-

tent does not exceed 10%. Gasohol

containing methanol is not recom-

mended by Yamaha because it can

cause damage to the fuel system or ve-

hicle performance problems.

This model is equipped with a catalytic

converter in the exhaust system.

EWA10860

WARNING

The exhaust system is hot after op-

eration. Make sure that the exhaust

system has cooled down before do-

ing any maintenance work.

ECA10700

CAUTION:

1. Rider seat

2. Passenger seat

The following precautions must be

observed to prevent a fire hazard or

other damages.

^GUse only unleaded gasoline.

The use of leaded gasoline will

cause unrepairable damage to

the catalytic converter.

^GNever park the vehicle near pos-

sible fire hazards such as grass

or other materials that easily

burn.

^GDo not allow the engine to idle

too long.

Rider seat

To open the rider seat

1. Place the scooter on the center-

stand.

2. Insert the key into the main switch,

and then turn it counterclockwise.

3-11

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INSTRUMENT AND CONTROL FUNCTIONS

To close the rider seat

1. Fold the rider seat down, and then

push it down to lock it in place.

2. Remove the key from the main

switch if the scooter will be left un-

attended.

To install the passenger seat

1. Insert the projections on the pas-

senger seat into the holders as

shown, place the passenger seat

in the original position, and then in-

stall the bolt.

NOTE:

Make sure that the rider seat is properly

secured before riding.

1. Open.

Passenger seat

NOTE:

Do not push inward when turning the

key.

To remove the passenger seat

1. Open the rider seat.

2. Remove the bolt, and then pull the

passenger seat forward.

3. Fold the rider seat up.

1. Passenger seat

2. Seat holder

2. Close the rider seat.

NOTE:

Make sure that the passenger seat is

properly secured before riding.

1. Rider seat

1. Passenger seat

2. Bolt

3-12

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INSTRUMENT AND CONTROL FUNCTIONS

EAU34150

EAU14492

Adjusting the rider seat

Storage compartments

Front storage compartment A

To open the storage compartment

when it is locked, insert the key in the

lock, turn it counterclockwise, and then

grasp the lock while pushing the button

in.

To open the storage compartment

when it is unlocked, simply grasp the

lock while pushing the button in.

1. Bolt

3. Slide the rider seat forward or

backward to the desired position.

4. Install bolts and securely tighten

them.

1. Rider seat

The rider seat can be adjusted as fol-

lows to change the riding position.

1. Open the rider seat. (See

page 3-11.)

5. Close the rider seat.

2. Remove the bolts.

1. Open.

2. Button

3. Lid

To lock the storage compartment, push

the lid into the original position, insert

the key in the lock, turn it clockwise,

3-13

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INSTRUMENT AND CONTROL FUNCTIONS

and then remove it.

1. Storage compartment opening lever

1. Rider seat

2. Lid

1. Lock.

2. Lid

ECA10080

CAUTION:

To close the storage compartment,

Front storage compartment B

To open the storage compartment,

slide the lever up, and then pull on the

lever.

push the lid into the original position.

Keep the following points in mind

when using the storage compart-

ment.

^GSince the storage compartment

accumulates heat when ex-

posed to the sun, do not store

anything susceptible to heat in-

side it.

^GTo avoid humidity from spread-

ing through the storage com-

partment, wrap wet articles in a

plastic bag before storing them

in the compartment.

EWA11160

WARNING

Do not store heavy items in this

compartment.

Rear storage compartment

Two helmets can be stored in the stor-

age compartment under the seats.

(See page 3-11.)

^GSince the storage compartment

may get wet while the scooter is

3-14

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INSTRUMENT AND CONTROL FUNCTIONS

EAU14890

being washed, wrap any articles

stored in the compartment in a

plastic bag.

handling and loss of stability may

result.

Adjusting the shock absorber

assemblies

Adjust the spring preload as follows.

To increase the spring preload and

thereby harden the suspension, turn

the adjusting ring on each shock ab-

sorber assembly in direction (a). To de-

crease the spring preload and thereby

soften the suspension, turn the adjust-

ing ring on each shock absorber as-

sembly in direction (b).

G Do not keep anything valuable

or breakable in the storage com-

partment.

ECA11100

CAUTION:

Do not leave the rider seat open for

an extended period of time, other-

wise the light may cause the battery

to discharge.

(a)

(b)

NOTE:

EWA11170

^GAlign the appropriate notch in the

adjusting ring with the position in-

dicator on the shock absorber.

^GUse the spring preload adjusting

tool included in the owner’s tool kit

to make this adjustment.

1. Spring preload adjusting ring

2. Position indicator

3. Spring preload adjusting tool

WARNING

Do not exceed the following loading

limits:

^GFront storage compartment A:

2 kg (4 lb)

^GRear storage compartment: 5 kg

(11 lb)

Each shock absorber assembly is

equipped with a spring preload adjust-

ing ring.

ECA10100

CAUTION:

Spring preload setting:

Minimum (soft):

^GMaximum load for the vehicle:

196 kg (432 lb)

Never attempt to turn an adjusting

mechanism beyond the maximum or

minimum settings.

Standard:

Maximum (hard):

EWA10210

WARNING

Always adjust both shock absorber

assemblies equally, otherwise poor

3-15

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INSTRUMENT AND CONTROL FUNCTIONS

EAU15301

EAU15372

Ignition circuit cut-off system

The ignition circuit cut-off system (com-

prising the sidestand switch and brake

light switches) has the following func-

tions.

pair it if it does not function proper-

ly.

Sidestand

The sidestand is located on the left side

of the frame. Raise the sidestand or

lower it with your foot while holding the

vehicle upright.

G It prevents starting when the side-

stand is up, but neither brake is ap-

plied.

^GIt prevents starting when either

brake is applied, but the sidestand

is still down.

^GIt cuts the running engine when the

sidestand is moved down.

Periodically check the operation of the

ignition circuit cut-off system according

NOTE:

The built-in sidestand switch is part of

the ignition circuit cut-off system, which

cuts the ignition in certain situations.

(See further down for an explanation of

the ignition circuit cut-off system.)

EWA10240

WARNING

The vehicle must not be ridden with

the sidestand down, or if the side-

stand cannot be properly moved up

(or does not stay up), otherwise the

sidestand could contact the ground

and distract the operator, resulting

to the following procedure.

EWA10250

WARNING

If a malfunction is noted, have a

Yamaha dealer check the system be-

fore riding.

possible loss of control.

Yamaha’s ignition circuit cut-off

system has been designed to assist

the operator in fulfilling the respon-

sibility of raising the sidestand be-

fore starting off. Therefore, check

this system regularly as described

below and have a Yamaha dealer re-

3-16

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INSTRUMENT AND CONTROL FUNCTIONS

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.

NOTE:

This check is most reliable if performed with

a warmed-up engine.

4. Keep the front or rear brake applied.

5. Push the start switch.

Does the engine start?

The sidestand switch may be defective.

The scooter should not be ridden until

checked by a Yamaha dealer.

YES

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?

The brake switch may be defective.

The scooter should not be ridden until

checked by a Yamaha dealer.

YES

With the engine still running:

9. Move the sidestand down.

Does the engine stall?

The sidestand switch may be defective.

The scooter should not be ridden until

checked by a Yamaha dealer.

YES

The system is OK. The scooter can be ridden.

3-17

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PRE-OPERATION CHECKS

EAU15593

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 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 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.

4-1

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PRE-OPERATION CHECKS

EAU15605

Pre-operation check list

ITEM

CHECKS

PAGE

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.

Fuel

3-10

Check oil level in engine.

If necessary, add recommended oil to speciﬁed level.

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.

Engine oil

6-14

6-17

Final transmission oil

Coolant

6-18

Front brake

Replace if necessary.

Check ﬂuid level in reservoir.

6-26, 6-28

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.

Rear brake

Replace if necessary.

Check ﬂuid level in reservoir.

6-26, 6-28

6-23, 6-30

If necessary, add recommended brake ﬂuid to speciﬁed level.

Check hydraulic system for leakage.

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.

Throttle grip

4-2

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PRE-OPERATION CHECKS

ITEM

CHECKS

PAGE

Check for damage.

Check tire condition and tread depth.

Check air pressure.

Wheels and tires

6-23, 6-25

Correct if necessary.

Make sure that operation is smooth.

Lubricate lever pivoting points if necessary.

Make sure that operation is smooth.

Lubricate pivots if necessary.

Make sure that all nuts, bolts and screws are properly tightened.

Tighten if necessary.

Check operation.

Correct if necessary.

Check operation of ignition circuit cut-off system.

If system is defective, have Yamaha dealer check vehicle.

Brake levers

6-30

6-31

—

Centerstand, sidestand

Chassis fasteners

Instruments, lights, signals

and switches

—

Sidestand switch

3-16

4-3

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OPERATION AND IMPORTANT RIDING POINTS

EAU15980

EWA10870

EAU34460

start switch, wait a few seconds, and

Starting the engine

then try again. Each starting attempt

should be as short as possible to pre-

serve the battery. Do not crank the en-

gine more than 10 seconds on any one

attempt.

ECA10250

WARNING

CAUTION:

^GBecome thoroughly familiar See page 5-3 for engine break-in in-

with all operating controls and structions prior to operating the ve-

their functions before riding. hicle for the first time.

ECA11040

Consult a Yamaha dealer re-

In order for the ignition circuit cut-off

garding any control or function

system to enable starting, the side-

that you do not thoroughly un-

stand must be up.

CAUTION:

For maximum engine life, never ac-

celerate hard when the engine is

cold!

derstand.

EWA10290

^GNever start the engine or oper-

ate it in a closed area for any

length of time. Exhaust fumes

are poisonous, and inhaling

them can cause loss of con-

sciousness and death within a

short time. Always make sure

that there is adequate ventila-

tion.

WARNING

^GBefore starting the engine,

check the function of the igni-

tion circuit cut-off system ac-

cording to the procedure

described on page 3-16.

^GNever ride with the sidestand

down.

1. Turn the key to “ON” and make

sure that the engine stop switch is

set to “ ”.

^GFor safety, always start the en-

gine with the centerstand down.

2. Close the throttle completely.

3. Start the engine by pushing the

start switch while applying the front

or rear brake.

NOTE:

If the engine does not start, release the

5-1

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OPERATION AND IMPORTANT RIDING POINTS

EAU16760

EAU16780

EAU16792

Starting off

NOTE:

Before starting off, allow the engine to

warm up.

Acceleration and deceleration Braking

1. Close the throttle completely.

2. Apply both front and rear brakes

simultaneously while gradually in-

creasing the pressure.

1. While pulling the rear brake lever

with your left hand and holding the

grab bar with your right hand, push

the scooter off the centerstand.

(b)

(a)

Front

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 throt-

tle grip in direction (b).

1. Grab bar

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 (on

the right) in order to take off.

5. Switch the turn signal off.

5-2

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OPERATION AND IMPORTANT RIDING POINTS

EAU16841

Rear

cult.

Engine break-in

There is never a more important period

in the life of your engine than the period

between 0 and 1600 km (1000 mi). For

this reason, you should read the follow-

ing material carefully.

Since the engine is brand new, do not

put an excessive load on it for the first

1600 km (1000 mi). The various parts in

the engine wear and polish themselves

to the correct operating clearances.

During this period, prolonged full-throt-

tle operation or any condition that might

result in engine overheating must be

avoided.

EWA10300

WARNING

^GAvoid braking hard or suddenly

(especially when leaning over to

one side), otherwise the scooter

may skid or overturn.

^GRailroad crossings, streetcar

rails, iron plates on road con-

struction sites, and manhole

covers become extremely slip-

pery when wet. Therefore, slow

down when approaching such

areas and cross them with cau-

tion.

EAU34320

0–1000 km (0–600 mi)

Avoid prolonged operation above 4000

r/min.

1000–1600 km (600–1000 mi)

Avoid prolonged operation above 6000

r/min.

ECA12930

^GKeep in mind that braking on a

wet road is much more difficult.

^GRide slowly down a hill, as brak-

ing downhill can be very diffi-

CAUTION:

After 1000 km (600 mi) of operation,

be sure to replace the engine oil, fi-

5-3

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OPERATION AND IMPORTANT RIDING POINTS

EAU17212

nal transmission oil and the oil filter

element.

Parking

When parking, stop the engine, and

then remove the key from the main

1600 km (1000 mi) and beyond

The vehicle can now be operated nor-

switch.

mally.

EWA10310

ECA10310

WARNING

CAUTION:

^GKeep the engine speed out of

the tachometer red zone.

^GIf any engine trouble should oc-

cur during the engine break-in

^GSince the engine and exhaust

system can become very hot,

park in a place where pedestri-

ans or children are not likely to

touch them.

^GDo not park on a slope or on soft

ground, otherwise the vehicle

may overturn.

period, immediately have

Yamaha dealer check the vehi-

cle.

ECA10380

CAUTION:

Never park in an area where there

are fire hazards such as grass or

other flammable materials.

5-4

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17271

EAU17301

rapid engine wear may result. Con-

sult a Yamaha dealer for proper

maintenance intervals.

PERIODIC MAINTENANCE

Safety is an obligation of the owner. Pe-

riodic inspection, adjustment and lubri-

cation will keep your vehicle in the

safest and most efficient condition pos-

sible. The most important points of

scooter inspection, adjustment, and lu-

brication are explained on the following

pages.

Maintenance, replacement, or repair of

the emission control devices and sys-

tems may be performed by any repair

establishment or individual that is certi-

PROPER PERIODIC MAINTENANCE

OF YOUR VEHICLE IS IMPORTANT

IN ORDER TO ENJOY LONG, PLEA-

SURABLE SERVICE. ESPECIALLY

IMPORTANT ARE THE MAINTE-

NANCE SERVICES RELATED TO

EMISSIONS CONTROL. THESE

CONTROLS NOT ONLY FUNCTION

TO ENSURE CLEANER AIR, BUT

ARE ALSO VITAL TO PROPER EN-

GINE OPERATION AND MAXIMUM

PERFORMANCE. IN THE FOLLOW-

fied (if applicable).

ING

PERIODIC

MAINTENANCE

EWA10320

CHARTS, THE SERVICES RELATED

TO EMISSIONS CONTROL ARE

GROUPED SEPARATELY. THESE

SERVICES REQUIRE SPECIALIZED

DATA, KNOWLEDGE, AND EQUIP-

MENT. YAMAHA DEALERS ARE

TRAINED AND EQUIPPED TO PER-

FORM THESE PARTICULAR SER-

VICES.

WARNING

If you are not familiar with mainte-

nance work, have a Yamaha dealer

do it for you.

EWA10330

WARNING

This scooter is designed for use on

paved roads only. If this scooter is

operated in abnormally dusty, mud-

dy or wet conditions, the air filter el-

ement should be cleaned or

replaced more frequently, otherwise

6-1

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17501

NOTE:

Owner’s tool kit

If you do not have the tools or experi-

ence required for a particular job, have

a Yamaha dealer perform it for you.

EWA10350

WARNING

Modifications not approved by

Yamaha may cause loss of perfor-

mance and render the vehicle un-

safe for use. Consult a Yamaha

dealer before attempting any chang-

1. Storage compartment mat

es.

2. Owner’s tool kit

The owner’s tool kit is located inside the

rear storage compartment. (See

page 3-13.)

Pull up the storage compartment mat,

and then remove the owner’s tool kit.

The service information included in this

manual and the tools provided in the

owner’s tool kit are intended to assist

you in the performance of preventive

maintenance and minor repairs. How-

ever, additional tools such as a torque

wrench may be necessary to perform

certain maintenance work correctly.

6-2

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17600

Periodic maintenance chart for the emission control system

INITIAL

600 mi

(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)

ODOMETER READINGS

4000 mi

8000 mi 12000 mi 16000 mi

20000 mi

No.

ITEM

ROUTINE

1 month

6 months 12 months 18 months 24 months 30 months

Check fuel and vacuum hoses

for cracks or damage.

Replace if necessary.

Fuel line

√

Check condition.

Adjust gap and clean.

Replace every 10000 mi (16000

km) or 18 months.

Check and adjust valve clear-

ance when engine is cold.

Check breather hose for cracks

or damage.

Spark plug

Replace.

Valve clearance

Every 26600 mi (42000 km)

Crankcase breather

system

√

Replace if necessary.

Fuel injection

Check engine idle speed.

Check control system for dam-

age.

√

Evaporative emis-

sion control system

Replace if necessary.

Check the air cut-off valve, reed

valve, and hose for damage.

Replace any damaged parts.

Air induction system

√

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

6-3

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU32185

General maintenance and lubrication chart

INITIAL

ODOMETER READINGS

8000 mi 12000 mi 16000 mi

(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)

600 mi

4000 mi

20000 mi

No.

ITEM

ROUTINE

1 month

6 months 12 months 18 months 24 months 30 months

Air ﬁlter elements

V-belt case air ﬁlter

element

Replace.

Clean.

Every 12000 mi (19000 km)

√

Check operation, ﬂuid level, and

for ﬂuid leakage.

Replace brake pads if neces-

sary.

Check operation, ﬂuid level, and

for ﬂuid leakage.

Replace brake pads if neces-

sary.

Front brake

Rear brake

√

Check for cracks or damage.

Replace.

Check operation.

Brake hoses

Rear brake lock

Wheels

Every 4 years

√

Adjust.

Check runout and for damage.

Replace if necessary.

Check tread depth and for dam-

age.

Replace if necessary.

Check air pressure.

Correct if necessary.

Check bearings for smooth

operation.

Tires

√

Wheel bearings

Replace if necessary.

6-4

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PERIODIC MAINTENANCE AND MINOR REPAIR

INITIAL

ODOMETER READINGS

600 mi

4000 mi

8000 mi 12000 mi 16000 mi

20000 mi

No.

ITEM

ROUTINE

(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)

1 month

6 months 12 months 18 months 24 months 30 months

Check bearing assemblies for

looseness.

Moderately repack with lith-

ium-soap-based grease.

Check all chassis ﬁtting and fas-

teners.

√

Steering bearings

Chassis fasteners

Every 12000 mi (19000 km)

√

Correct if necessary.

Front brake lever

pivot shaft

Rear brake lever

pivot shaft

Apply silicone grease lightly.

√

Check operation.

Centerstand and

sidestand pivots

Apply lithium-soap-based

grease (all-purpose grease)

lightly.

Check operation and replace if

necessary.

Check operation and for oil leak-

age.

Replace if necessary.

Check operation and for oil leak-

age.

Replace if necessary.

Change. (See pages 3-3 and

6-14.)

Check oil level and vehicle for oil

leakage.

√

Sidestand switch

Front fork

√

Shock absorber

assemblies

√

When the oil change indicator ﬂashes (every 3125 mi (5000 km))

Engine oil

Every 3125 mi (5000 km)

6-5

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PERIODIC MAINTENANCE AND MINOR REPAIR

INITIAL

ODOMETER READINGS

8000 mi 12000 mi 16000 mi

(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)

600 mi

4000 mi

20000 mi

No.

ITEM

ROUTINE

1 month

6 months 12 months 18 months 24 months 30 months

Engine oil ﬁlter ele-

ment

Replace.

√

Every 12500 mi (20000 km)

Check coolant level and vehicle

for coolant leakage.

Change.

Check vehicle for oil leakage.

Change.

√

Cooling system

Every 3 years

Final transmission

oil

V-belt

Front and rear brake

switches

√

Replace.

When the V-belt replacement indicator ﬂashes (every 12500 mi (20000 km)).

Check operation.

√

Check operation and free play.

Adjust the throttle cable free

play if necessary.

Lubricate the throttle grip hous-

ing and cable.

Throttle grip hous-

ing and cable

Lights, signals and

switches

Check operation.

Adjust headlight beam.

√

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

NOTE:

From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.

6-6

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU36370

NOTE:

^GThe air filters and V-belt filter need more frequent service if you are riding in unusually wet or dusty areas.

^GHydraulic brake service

After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid

levels and fill the reservoirs as required.

Every two years replace the internal components of the brake master cylinders and calipers, and change the brake

fluid.

Replace the brake hoses every four years and if cracked or damaged.

6-7

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU18712

Removing and installing

cowlings and panels

The cowlings and panels shown need

to be removed to perform some of the

maintenance jobs described in this

chapter. Refer to this section each time

a cowling or panel needs to be re-

moved and installed.

3 4

1. Cowling D

1. Quick fastener

2. Cowling A

EAU34282

To install the cowling

1. Place the cowling in the original

position, and then install the quick

fasteners.

Cowling A

To remove the cowling

1. Open the rider seat. (See

page 3-11.)

NOTE:

To install the quick fastener, push the

2. Remove the quick fasteners in the center pin out so that it will protrude

rear storage compartment, and from the fastener head, insert the fas-

then pull the cowling off as shown. tener into the cowling, and then push

the protruding pin in until it is flush with

1. Panel A

2. Cowling C

3. Cowling A

4. Cowling B

5. Panel B

NOTE:

the fastener head.

The quick fastener is removed by push-

ing the center pin in with a screwdriver,

and then pulling the fastener out.

6. Cowling E

2. Close the rider seat.

6-8

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PERIODIC MAINTENANCE AND MINOR REPAIR

Cowling B

To install the cowling

Place the cowling in the original posi-

tion, and then install the screws.

To remove the cowling

1. Remove the screws.

Cowlings C and D

To remove one of the cowlings

1. Remove cowlings A and B.

2. Remove the passenger seat. (See

page 3-11.)

3. Remove the grab bar by removing

the grab bar bolts and collars.

1. Screw access cover

5. Remove the screws, and then pull

the cowling off.

1. Cowling B

2. Screw

2. Remove the cowling as shown.

1. Grab bar bolt

2. Collar

3. Grab bar

1. Screw

To install the cowling

4. Remove the screw access cover

by pulling it off.

1. Place the cowling in the original

position, and then install the

screws.

1. Cowling B

6-9

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PERIODIC MAINTENANCE AND MINOR REPAIR

2. Install the screw access cover by

placing it in its original position.

3. Install the grab bar by installing the

collars and grab bar bolts.

1. Left ﬂoorboard mat

1. Cowling E

2. Remove the cowling screws.

To install the cowling

1. Insert the projections on the cowl-

ing into the slots as shown, and

then install the screws.

Tightening torque:

Grab bar bolt:

23 Nm (2.3 m·kgf, 16.6 ft·lbf)

4. Install the passenger seat.

5. Install cowlings A and B.

Cowling E

1. Screw

To remove the cowling

1. Pull up the left floorboard mats as

shown.

3. Pull the cowling down slightly, and

then pull it outward as shown.

1. Projection

2. Place the left floorboard mats in

the original position.

6-10

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU34290

To install the panel

Place the panel in the original position,

Panel A

and then install the bolts.

To remove the panel

1. Remove the bolts.

1. Panel B

2. Screw

To install the panel

Panel B

Place the panel in the original position,

and then install the screws.

To remove the panel

Remove the screws, and then pull the

panel outward.

1. Bolt

2. Panel A

2. Pull the panel out as shown.

1. Screw

2. Panel B

6-11

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU34172

Checking the spark plug

The spark plug is an important engine

component, which is easy to check.

Since heat and deposits will cause any

spark plug to slowly erode, the spark

plug should be removed and checked

in accordance with the periodic mainte-

nance and lubrication chart. In addition,

the condition of the spark plug can re-

veal the condition of the engine.

1. Storage compartment mat

2. Spark plug cover

3. Screw

1. Spark plug wrench

To check the spark plug

To remove the spark plug

1. Open the rider seat. (See

page 3-11.)

1. Check that the porcelain insulator

around the center electrode of the

spark plug is a medium-to-light tan

(the ideal color when the vehicle is

ridden normally).

3. Remove the spark plug cap.

2. Pull up the storage compartment

mat, and then remove the spark

plug cover by removing the

screws.

NOTE:

If the spark plug shows a distinctly dif-

ferent color, the engine could be oper-

ating improperly. Do not attempt to

diagnose such problems yourself. In-

stead, have a Yamaha dealer check

the vehicle.

1. Spark plug cap

2. Check the spark plug for electrode

erosion and excessive carbon or

other deposits, and replace it if

4. Remove the spark plug as shown,

with the spark plug wrench includ-

ed in the owner’s tool kit.

6-12

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PERIODIC MAINTENANCE AND MINOR REPAIR

necessary.

3. Install the spark plug with the

spark plug wrench, and then tight-

Specified spark plug:

NGK/CR7E

en it to the specified torque.

Tightening torque:

Spark plug:

To install the spark plug

1. Measure the spark plug gap with a

wire thickness gauge and, if nec-

essary, adjust the gap to specifica-

tion.

12.5 Nm (1.25 m·kgf, 9 ft·lbf)

NOTE:

If a torque wrench is not available when

installing a spark plug, a good estimate

of the correct torque is 1/4–1/2 turn

past finger tight. However, the spark

plug should be tightened to the speci-

fied torque as soon as possible.

1. Spark plug cap

2. Spark plug wire clamp

5. Install the spark plug cover by in-

stalling the screws.

6. Place the storage compartment

mat in the original position.

7. Close the rider seat.

4. Install the spark plug cap.

NOTE:

Make sure the spark plug wire is fas-

tened in the clamp as shown.

1. Spark plug gap

Spark plug gap:

0.7–0.8 mm (0.028–0.031 in)

2. Clean the surface of the spark plug

gasket and its mating surface, and

then wipe off any grime from the

spark plug threads.

6-13

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU36110

EAU34182

NOTE:

Canister

Engine oil and oil filter

element

The engine oil should be between the

minimum and maximum level marks.

The engine oil level should be checked

before each ride. In addition, the oil

must be changed and the oil filter ele-

ment replaced at the intervals specified

in the periodic maintenance and lubri-

cation chart and when the oil change in-

dicator comes on.

To check the engine oil level

1. Place the vehicle on the center-

stand.

This model is equipped with a canister

to prevent the discharging of fuel vapor

into the atmosphere. Before operating

this vehicle, make sure to check the fol-

lowing:

1. Engine oil ﬁller cap

2. Maximum level mark

3. Minimum level mark

NOTE:

Make sure that the vehicle is positioned

straight up when checking the oil level.

G Check each hose connection.

4. If the engine oil is below the mini-

mum level mark, add sufficient oil

of the recommended type to raise

it to the correct level.

5. Insert the dipstick into the oil filler

hole, and then tighten the oil filler

cap.

^GCheck each hose and canister for A slight tilt to the side can result in a

cracks or damage. Replace if false reading.

damaged.

2. Start the engine, warm it up for

^GMake sure that the canister breath-

several minutes, and then turn it

er is not blocked, and if necessary,

off.

clean it.

3. Wait a few minutes until the oil set-

tles, remove the oil filler cap, wipe

the dipstick clean, insert it back

into the oil filler hole (without

screwing it in), and then remove it

again to check the oil level.

6-14

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PERIODIC MAINTENANCE AND MINOR REPAIR

To change the engine oil (with or

without oil filter element replace-

ment)

1. Start the engine, warm it up for

several minutes, and then turn it

off.

2. Place an oil pan under the engine

to collect the used oil.

3. Remove the engine oil filler cap

and the engine oil drain bolt to

drain the oil from the crankcase.

1. Engine oil drain bolt

2. Washer

1. Bolt

2. Oil ﬁlter element cover

6. Remove and replace the oil filter

element and O-rings.

NOTE:

Skip steps 5–7 if the oil filter element is

not being replaced.

5. Remove the oil filter element cover

by removing the bolts.

1. Engine oil drain bolt

4. Check the washer for damage and

replace it if necessary.

6-15

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PERIODIC MAINTENANCE AND MINOR REPAIR

Tightening torque:

Oil filter element cover bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Recommended engine oil:

See page 8-1.

Oil quantity:

Without oil filter element replace-

ment:

1.50 L (1.59 US qt) (1.32 Imp.qt)

With oil filter element replacement:

1.70 L (1.80 US qt) (1.50 Imp.qt)

NOTE:

Make sure that the O-rings are properly

seated.

8. Install the washer and the engine

oil drain bolt, and then tighten the

drain bolt to the specified torque.

NOTE:

Be sure to wipe off spilled oil on any

parts after the engine and exhaust sys-

tem have cooled down.

1. Oil ﬁlter element cover

2. O-ring

3. Compression spring

4. Oil ﬁlter element

Tightening torque:

Engine oil drain bolt:

ECA11670

20 Nm (2.0 m·kgf, 14.5 ft·lbf)

ECA12910

CAUTION:

G Do not use oils with a diesel

specification of “CD” or oils of a

higher quality than specified. In

addition, do not use oils labeled

“ENERGY CONSERVING II” or

higher.

NOTE:

When removing the oil filter element

cover, the compression spring will

fall out. Take care not to lose the

compression spring.

Make sure that the washer is properly

seated.

9. Add the specified amount of the

recommended engine oil, and then

install and tighten the oil filler cap.

7. Install the compression spring and

oil filter element cover by installing

the bolts, then tightening them to

the specified torque.

G Be sure no foreign material en-

ters the crankcase.

10. Start the engine, and then let it idle

for several minutes while checking

it for oil leakage. If oil is leaking, im-

mediately turn the engine off and

check for the cause.

6-16

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU20061

11. Reset the oil change indicator ac- the correct time. To reset the oil change

Final transmission oil

cording to the following procedure. indicator before the periodic oil change

interval has been reached, follow the

The final transmission case must be

checked for oil leakage before each

ride. If any leakage is found, have a

Yamaha dealer check and repair the

scooter. In addition, the final transmis-

sion oil must be changed as follows at

the intervals specified in the periodic

maintenance and lubrication chart.

1. Start the engine, warm up the final

transmission oil by riding the

scooter for several minutes, and

then stop the engine.

To reset the oil change indicator

1. Turn the key to “ON”.

above procedure, but note that the indi-

cator will come on for 1.4 seconds after

2. Hold the “OIL CHANGE” button releasing the “OIL CHANGE” button,

pushed for two to eight seconds.

otherwise repeat the procedure.

2. Place the scooter on the center-

stand.

3. Place an oil pan under the final

transmission case to collect the

used oil.

4. Remove the oil filler cap and drain

bolt to drain the oil from the final

transmission case.

1. “OIL CHANGE” button

3. Release the “OIL CHANGE” but-

ton, and the oil change indicator

will go off.

NOTE:

If the engine oil is changed before the

oil change indicator comes on (i.e. be-

fore the periodic oil change interval has

been reached), the indicator must be

reset after the oil change for the next

periodic oil change to be indicated at

6-17

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU20070

EWA11310

Coolant

WARNING

The coolant level should be checked

before each ride. In addition, the cool-

ant must be changed at the intervals

specified in the periodic maintenance

and lubrication chart.

^GMake sure that no foreign mate-

rial enters the final transmission

case.

^GMake sure that no oil gets on the

tire or wheel.

EAU34192

7. Check the final transmission case

for oil leakage. If oil is leaking,

check for the cause.

To check the coolant level

1. Place the vehicle on a level sur-

face and hold it in an upright posi-

tion.

1. Final transmission oil ﬁller cap

2. Final transmission oil drain bolt

5. Install the final transmission oil

drain bolt, and then tighten it to the

specified torque.

NOTE:

^GThe coolant level must be checked

on a cold engine since the level

varies with engine temperature.

^GMake sure that the vehicle is posi-

tioned straight up when checking

the coolant level. A slight tilt to the

side can result in a false reading.

Tightening torque:

Final transmission oil drain bolt:

20 Nm (2.0 m·kgf, 14.5 ft·lbf)

6. Add the specified amount of the

recommended final transmission

oil, and then install and tighten the

oil filler cap.

2. Pull up the right floorboard mat as

shown.

Recommended final transmission

oil:

See page 8-1.

Oil quantity:

0.25 L (0.26 US qt) (0.22 Imp.qt)

6-18

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PERIODIC MAINTENANCE AND MINOR REPAIR

ECA10471

NOTE:

CAUTION:

^GIf coolant is not available, use

The coolant should be between the

minimum and maximum level marks.

distilled water or soft tap water

5. If the coolant is at or below the

minimum level mark, open the

coolant reservoir cap, add coolant

to the maximum level mark, and

then close the coolant reservoir

cap.

instead. Do not use hard water

or salt water since it is harmful

to the engine.

^GIf water has been used instead

of coolant, replace it with cool-

ant as soon as possible, other-

wise the cooling system will not

be protected against frost and

corrosion.

^GIf water has been added to the

coolant, have a Yamaha dealer

check the antifreeze content of

the coolant as soon as possible,

otherwise the effectiveness of

the coolant will be reduced.

1. Right ﬂoorboard mat

3. Remove the coolant reservoir cov-

er by removing the screw.

EWA10380

1. Minimum level mark

2. Maximum level mark

3. Coolant reservoir cap

WARNING

Never attempt to remove the radiator

cap when the engine is hot.

1. Screw

2. Coolant reservoir cover

Coolant reservoir capacity (up to the

maximum level mark):

0.32 L (0.34 US qt) (0.28 Imp.qt)

6. Install the coolant reservoir cover

by installing the screw.

7. Place the right floorboard mat in

the original position.

4. Check the coolant level in the cool-

ant reservoir.

6-19

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU34204

Left

NOTE:

Air filter elements and check

hoses and V-belt case air filter

element

^GThe radiator fan is automatically

switched on or off according to the

coolant temperature in the radia-

The air filter elements and the V-belt

tor.

case air filter element should be ser-

^GIf the engine overheats, see page

viced at the intervals specified in the

6-40 for further instructions.

periodic maintenance and lubrication

chart. Service all air filter elements

more frequently if you are riding in un-

usually wet or dusty areas.

1. Screw

2. Air ﬁlter case cover

3. Rubber cap

Replacing the air filter elements

1. Place the scooter on the center-

stand.

Right

NOTE:

Continue as follows for each air filter el-

ement.

2. Remove the air filter case cover by

removing the rubber cap and

screws.

1. Screw

2. Air ﬁlter case cover

3. Rubber cap

3. Pull the air filter element out.

6-20

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PERIODIC MAINTENANCE AND MINOR REPAIR

Left

6. Install the rubber cap.

Left

ECA12922

CAUTION:

^GMake sure that each filter ele-

ment is properly seated in its

case.

^GAlways replace both air filter el-

ements at the same time, other-

wise poor engine performance

or damage to the engine may re-

sult.

^GThe engine should never be op-

erated without the filter ele-

ments installed, otherwise the

piston(s) and/or cylinder(s) may

become excessively worn.

1. Air ﬁlter element

1. Air ﬁlter check hose

Right

To clean the air filter check hoses

1. Check the hose at the bottom of

both air filter cases for accumulat-

ed dirt or water.

1. Air ﬁlter element

1. Air ﬁlter check hose

4. Insert a new air filter element into

the air filter case.

5. Install the air filter case cover by in-

stalling the screws.

2. If dirt or water is visible, remove

the hose, clean it, and then install

it.

6-21

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PERIODIC MAINTENANCE AND MINOR REPAIR

Cleaning the V-belt case air filter el-

necessary.

ement

1. Remove

8. Install the V-belt case air filter ele-

ment by installing the screws.

9. Install the V-belt air filter case cov-

cowling

(See

page 6-8.)

2. Remove panel B. (See page 6-8.)

3. Remove the left air filter case cov-

er.

4. Remove the V-belt air filter case

cover by removing the screws.

er by installing the screws.

ECA12940

CAUTION:

Make sure that the V-belt filter ele-

ment is properly seated in its case.

10. Install the left air filter case cover.

11. Install the panel.

12. Install the cowling.

1. Screw

2. V-belt case air ﬁlter element

6. Lightly tap the V-belt case air filter

element to remove most of the

dust and dirt, and then blow out the

dirt with compressed air as shown.

1. Screw

2. V-belt air ﬁlter case cover

5. Remove the V-belt case air filter

element by removing the screws.

7. Check the V-belt case air filter ele-

ment for damage and replace it if

6-22

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU21382

EAU21401

EAU21861

Checking the throttle cable

free play

Valve clearance

Tires

The valve clearance changes with use, To maximize the performance, durabil-

resulting in improper air-fuel mixture ity, and safe operation of your scooter,

and/or engine noise. To prevent this note the following points regarding the

from occurring, the valve clearance specified tires.

must be adjusted by a Yamaha dealer

at the intervals specified in the periodic Tire air pressure

maintenance and lubrication chart.

The tire air pressure should be checked

and, if necessary, adjusted before each

ride.

EWA10500

WARNING

^GThe tire air pressure must be

checked and adjusted on cold

tires (i.e., when the temperature

of the tires equals the ambient

temperature).

^GThe tire air pressure must be ad-

justed in accordance with the

riding speed and with the total

weight of rider, passenger, car-

go, and accessories approved

for this model.

1. Throttle cable free play

The throttle cable free play should mea-

sure 3.0–5.0 mm (0.12–0.20 in) at the

throttle grip. Periodically check the

throttle cable free play and, if neces-

sary, have a Yamaha dealer adjust it.

6-23

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PERIODIC MAINTENANCE AND MINOR REPAIR

LOAD YOUR VEHICLE. Make sure the sidewall is cracked, have a Yamaha

that the total weight of the cargo, rid- dealer replace the tire immediately.

Tire air pressure (measured on cold

tires):

er, passenger, and accessories

0–90 kg (0–198 lb):

Front:

Minimum tire tread depth (front and

(cowling, saddlebags, etc. if ap-

rear):

proved for this model) does not ex-

1.0 mm (0.04 in)

200 kPa (29 psi) (2.00 kgf/cm )

Rear:

ceed the maximum load of the

250 kPa (36 psi) (2.50 kgf/cm )

vehicle. Operation of an overloaded

vehicle could cause tire damage, an

The tire tread depth limits may differ

accident, or even injury.

NOTE:

90–196 kg (198–432 lb):

Front:

200 kPa (29 psi) (2.00 kgf/cm )

from country to country. Always comply

Rear:

with the local regulations.

250 kPa (36 psi) (2.50 kgf/cm )

Tire inspection

Maximum load*:

196 kg (432 lb)

* Total weight of rider, passenger, car-

go and accessories

Tire information

This scooter is equipped with cast

wheels and tubeless tires with valves.

EWA10510

EWA10590

WARNING

Proper loading of your vehicle is im-

portant for several characteristics of

your vehicle, such as handling,

braking, performance and safety. Do

not carry loosely packed items that

can shift. Securely pack your heavi-

est items close to the center of the

vehicle, and distribute the weight

evenly from side to side. Properly

adjust the suspension for your load,

and check the condition and pres-

sure of your tires. NEVER OVER-

Operating the scooter with exces-

sively worn tires decrease riding

stability and can lead to loss of con-

trol. Have excessively worn tires re-

placed by

Yamaha dealer

1. Tire sidewall

2. Tire tread depth

immediately. Brakes, tires, and relat-

ed wheel parts replacement should

be left to a Yamaha Service Techni-

cian.

3. Tire wear indicator

The tires must be checked before each

ride. If a tire tread shows crosswise

lines (minimum tread depth), if the tire

has a nail or glass fragments in it, or if

6-24

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU21992

Front tire:

Cast wheels

Size:

To maximize the performance, durabil-

ity, and safe operation of your vehicle,

note the following points regarding the

specified wheels.

120/80-14M/C 58S

Manufacturer/model:

IRC/MB67

DUNLOP/D305FL

Rear tire:

Size:

150/70-13M/C 64S

Manufacturer/model:

IRC/MB67

G The wheel rims should be checked

for cracks, bends, warpage or

damage before each ride. If any

damage is found, have a Yamaha

dealer replace the wheel. Do not

attempt even the smallest repair to

the wheel. A deformed or cracked

wheel must be replaced.

^GThe wheel should be balanced

whenever either the tire or wheel

has been changed or replaced. An

unbalanced wheel can result in

poor performance, adverse han-

dling characteristics, and a short-

ened tire life.

1. Valve stem nut

2. Valve stem locknut

DUNLOP/D305L

EWA10580

WARNING

Tightening torques:

Valve stem nut:

1.5 Nm (0.2 m·kgf, 1.1 ft·lbf)

Valve stem locknut:

^GIt is dangerous to ride with a

worn-out tire. When a tire tread

begins to show crosswise lines,

have a Yamaha dealer replace

the tire immediately.

^GThe replacement of all wheel-

and brake-related parts, includ-

ing the tires, should be left to a

Yamaha dealer, who has the

necessary professional knowl-

edge and experience.

3.0 Nm (0.3 m·kgf, 2.2 ft·lbf)

G Ride at moderate speeds after

changing a tire since the tire sur-

face must first be “broken in” for it

to develop its optimal characteris-

tics.

G After repairing or replacing the rear

tire, tighten the valve stem nut and

locknut to the specified torques.

6-25

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU22011

EAU33453

been approved by Yamaha.

Accessories and replacement

Front and rear brake lever free

parts

play

EWA10621

WARNING

Front

This vehicle is not designed to pull a

trailer or to be attached to a sidecar.

The accessories or replacement

parts you choose for your vehicle

should be designed specifically for

this model, and they must be se-

curely mounted to maintain the in-

herent stability of the original

design. Genuine Yamaha Parts and

Accessories are designed and test-

ed to be compatible with your vehi-

cle. Please consider Genuine

Yamaha Parts and Accessories be-

fore making a purchase. Use of

non-Yamaha-approved accessories

or replacement parts may cause

loss of handling stability and riding

safety. Since Yamaha cannot con-

trol the quality of accessories or

parts manufactured by other compa-

nies, Yamaha cannot be held liable

for any consequences caused by

the use of items which have not

Rear

There should be no free play at the

brake lever ends. If there is free play,

have a Yamaha dealer inspect the

6-26

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU33473

brake system.

To decrease the rear brake lock lever

cable length, turn the adjusting nut in

EWA14211

Adjusting the rear brake lock

lever cable

WARNING

direction (b).

EWA10650

A soft or spongy feeling in the brake

lever can indicate the presence of air

in the hydraulic system. If there is air

in the hydraulic system, have a

Yamaha dealer bleed the system be-

fore operating the vehicle. Air in the

hydraulic system will diminish the

braking performance, which may re-

sult in loss of control and an acci-

dent.

WARNING

If proper adjustment cannot be ob-

tained as described, have a Yamaha

dealer make this adjustment.

(b)

(a)

1. Adjusting nut

2. Rear brake lock lever cable length

Rear brake lock lever cable adjustment

may be required if the rear brake lock

lever does not hold properly. When the

rear brake lock lever is not in use, the

rear brake lock lever cable length

should measure 45 mm to 47 mm (1.77

in to 1.85 in) at the rear brake caliper.

Periodically check the rear brake lock

lever cable length and, if necessary,

adjust it as follows.

To increase the rear brake lock lever

cable length, turn the adjusting nut at

the rear brake caliper in direction (a).

6-27

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU22390

EAU22580

indicator groove has almost disap-

peared, have a Yamaha dealer replace

the brake pads as a set.

Checking the front and rear

Checking the brake fluid level

brake pads

Front brake

The front and rear brake pads must be

checked for wear at the intervals spec-

ified in the periodic maintenance and

lubrication chart.

EAU34210

Rear brake pads

Have a Yamaha dealer check each

rear brake pad for damage and mea-

sure the lining thickness and if neces-

sary, replace them as a set.

EAU22420

Front brake pads

1. Minimum level mark

Rear brake

1. Wear indicator groove

Each front brake pad is provided with a

wear indicator groove, which allows

you to check the brake pad wear with-

out having to disassemble the brake.

To check the brake pad wear, check

the wear indicator groove. If a brake

pad has worn to the point that the wear

1. Minimum level mark

Insufficient brake fluid may allow air to

6-28

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU22730

enter the brake system, possibly caus-

ing it to become ineffective.

refilling. Water will significantly

Changing the brake fluid

Have a Yamaha dealer change the

brake fluid at the intervals specified in

the NOTE after the periodic mainte-

nance and lubrication chart. In addition,

have the oil seals of the master cylin-

ders and calipers as well as the brake

hoses replaced at the intervals listed

below or whenever they are damaged

or leaking.

lower the boiling point of the fluid

and may result in vapor lock.

G Brake fluid may deteriorate paint-

ed surfaces or plastic parts. Al-

ways clean up spilled fluid

immediately.

G As the brake pads wear, it is nor-

mal for the brake fluid level to grad-

ually go down. However, if the

brake fluid level goes down sud-

denly, have a Yamaha dealer

check the cause.

Before riding, check that the brake fluid

is above the minimum level mark and

replenish if necessary. A low brake fluid

level may indicate worn brake pads

and/or brake system leakage. If the

brake fluid level is low, be sure to check

the brake pads for wear and the brake

system for leakage.

Observe these precautions:

G Oil seals: Replace every two

years.

G Brake hoses: Replace every four

years.

^GWhen checking the fluid level,

make sure that the top of the brake

fluid reservoir is level.

G Use only the recommended quality

brake fluid, otherwise the rubber

seals may deteriorate, causing

leakage and poor braking perfor-

mance.

Recommended brake fluid:

DOT 4

G Refill with the same type of brake

fluid. Mixing fluids may result in a

harmful chemical reaction and

lead to poor braking performance.

G Be careful that water does not en-

ter the brake fluid reservoir when

6-29

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23091

EAU23111

EAU23172

Checking and lubricating the

cables

Checking and lubricating the

throttle grip and cable

Lubricating the front and rear

brake levers

The operation of all control cables and The operation of the throttle grip should

the condition of the cables should be be checked before each ride. In addi-

checked before each ride, and the ca- tion, the cable should be lubricated at

bles and cable ends should be lubricat- the intervals specified in the periodic

ed if necessary. If a cable is damaged maintenance chart.

or does not move smoothly, have a

Yamaha dealer check or replace it.

Recommended lubricant:

Yamaha Chain and Cable Lube or

engine oil SAE 10W-30

The pivoting points of the front and rear

brake levers must be lubricated at the

intervals specified in the periodic main-

tenance and lubrication chart.

EWA10710

WARNING

Damage to the outer housing of ca-

bles may result in internal rusting

and cause interference with cable

movement. Replace damaged ca-

bles as soon as possible to prevent

unsafe conditions.

Recommended lubricant:

Silicone grease

6-30

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23211

EAU23271

EWA10740

Checking and lubricating the

centerstand and sidestand

Checking the front fork

WARNING

The condition and operation of the front

fork must be checked as follows at the

intervals specified in the periodic main-

tenance and lubrication chart.

If the centerstand or sidestand does

not move up and down smoothly,

have a Yamaha dealer check or re-

pair it.

To check the condition

Recommended lubricant:

Lithium-soap-based grease (all-pur-

pose grease)

EWA10750

WARNING

Securely support the vehicle so that

there is no danger of it falling over.

Check the inner tubes for scratches,

damage and excessive oil leakage.

To check the operation

1. Place the vehicle on a level sur-

face and hold it in an upright posi-

tion.

2. While applying the front brake,

push down hard on the handlebars

several times to check if the front

fork compresses and rebounds

smoothly.

The operation of the centerstand and

sidestand should be checked before

each ride, and the pivots and met-

al-to-metal contact surfaces should be

lubricated if necessary.

6-31

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23280

Checking the steering

Worn or loose steering bearings may

cause danger. Therefore, the operation

of the steering must be checked as fol-

lows at the intervals specified in the pe-

riodic maintenance and lubrication

chart.

1. Place a stand under the engine to

raise the front wheel off the

ECA10590

ground.

CAUTION:

EWA10750

WARNING

Securely support the vehicle so that

there is no danger of it falling over.

If any damage is found or the front

fork does not operate smoothly,

have a Yamaha dealer check or re-

pair it.

2. Hold the lower ends of the front

fork legs and try to move them for-

ward and backward. If any free

play can be felt, have a Yamaha

dealer check or repair the steering.

6-32

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23290

EAU34221

working near batteries. In case

of contact, administer the fol-

lowing FIRST AID.

Checking the wheel bearings

Battery

The front and rear wheel bearings must

be checked at the intervals specified in

the periodic maintenance and lubrica-

tion chart. If there is play in the wheel

hub or if the wheel does not turn

smoothly, have a Yamaha dealer check

the wheel bearings.

EXTERNAL: Flush with plenty

of water.

INTERNAL: Drink large quan-

tities of water or milk and im-

mediately call a physician.

EYES: Flush with water for 15

minutes and seek prompt

medical attention.

^GBatteries produce explosive hy-

drogen gas. Therefore, keep

sparks, flames, cigarettes, etc.,

away from the battery and pro-

vide sufficient ventilation when

charging it in an enclosed

space.

G KEEP THIS AND ALL BATTER-

IES OUT OF THE REACH OF

CHILDREN.

1. Battery

The battery is located behind cowling

A. (See page 6-8.)

This model is equipped with

sealed-type (MF) battery, which does

not require any maintenance. There is

no need to check the electrolyte or to

add distilled water.

EWA10760

WARNING

^GElectrolyte is poisonous and

dangerous since it contains sul-

furic acid, which causes severe

burns. Avoid any contact with

skin, eyes or clothing and al-

ways shield your eyes when

To charge the battery

Have a Yamaha dealer charge the bat-

tery as soon as possible if it seems to

have discharged. Keep in mind that the

battery tends to discharge more quickly

if the vehicle is equipped with optional

6-33

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU34232

electrical accessories.

er, have

charge your battery.

Yamaha dealer

Replacing the fuses

The main fuse and the fuse box, which

contains the fuses for the individual cir-

cuits, are located behind cowling A.

(See page 6-8.)

If a fuse is blown, replace it as follows.

1. Turn the key to “OFF” and turn off

the electrical circuit in question.

2. Remove the blown fuse, and then

install a new fuse of the specified

amperage.

To store the battery

1. If the vehicle will not be used for

more than one month, remove the

battery, fully charge it, and then

place it in a cool, dry place.

2. If the battery will be stored for more

than two months, check it at least

once a month and fully charge it if

necessary.

3. Fully charge the battery before in-

stallation.

4. After installation, make sure that

the battery leads are properly con-

NOTE:

If the main fuse is blown, remove the

grab bar to access the main fuse. After

replacing the main fuse, install the grab

bar. (See page 6-8.)

nected to the battery terminals.

ECA10630

CAUTION:

^GAlways

keep the battery

charged. Storing a discharged

battery can cause permanent

battery damage.

^GTo charge a sealed-type (MF)

battery, a special (constant-volt-

age) battery charger is required.

Using a conventional battery

charger will damage the battery.

If you do not have access to a

sealed-type (MF) battery charg-

6-34

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PERIODIC MAINTENANCE AND MINOR REPAIR

Specified fuses:

Main fuse:

40.0 A

Ignition fuse:

10.0 A

Signaling system fuse:

10.0 A

Headlight fuse:

20.0 A

Taillight fuse:

10.0 A

Radiator fan fuse:

10.0 A

Fuel injection system fuse:

10.0 A

Backup fuse:

10.0 A

1. Spare main fuse

2. Main fuse

1. Ignition fuse

2. Signaling system fuse

3. Headlight fuse

4. Radiator fan fuse

5. Backup fuse (for odometer and clock)

6. Fuel injection system fuse

7. Spare fuse

ECA10640

CAUTION:

Do not use a fuse of a higher amper-

age rating than recommended to

avoid causing extensive damage to

the electrical system and possibly a

fire.

1. Fuse box

2. Taillight fuse

3. Turn the key to “ON” and turn on

the electrical circuit in question to

check if the device operates.

4. If the fuse immediately blows

again, have a Yamaha dealer

check the electrical system.

6-35

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU34240

EAU24180

EAU36122

Replacing a headlight bulb

Tail/brake light

Replacing a front turn signal

This model is equipped with quartz bulb This model is equipped with an LED

headlights. If a headlight bulb burns type of tail/brake light.

out, have a Yamaha dealer replace it If the tail/brake light does not come on,

and, if necessary, adjust the headlight have a Yamaha dealer check it.

beam.

light bulb

1. Place the scooter on the center-

stand.

2. Remove panel A. (See page 6-8.)

3. Remove the windshield by remov-

ing the screws.

1. Screw

2. Windshield

4. Remove the front turn signal light

unit by removing the screws.

6-36

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU34260

clockwise.

Replacing a rear turn signal

7. Insert a new bulb into the socket,

push it in, and then turn it clock-

wise until it stops.

8. Install the socket (together with the

bulb) by turning it clockwise.

9. Place the turn signal light unit in

the original position, and then in-

stall the screws.

light bulb

1. Place the scooter on the center-

stand.

2. Remove cowling C for replacing

the left turn signal light bulb or

cowling D for replacing the right

turn signal light bulb. (See

page 6-8.)

1. Screw

2. Front turn signal light unit

3. Remove the socket (together with

the turn signal light bulb) by turning

it counterclockwise.

5. Remove the socket (together with

the bulb) by turning it counter-

clockwise.

10. Install the windshield by installing

the screws.

11. Install panel A.

1. Turn signal light bulb socket

4. Remove the defective bulb by

pushing it in and turning it counter-

clockwise.

1. Turn signal light bulb socket

6. Remove the defective bulb by

pushing it in and turning it counter-

5. Insert a new bulb into the socket,

6-37

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU34270

push it in, and then turn it clock-

wise until it stops.

6. Install the socket (together with the

bulb) by turning it clockwise.

7. Install the cowling removed.

Replacing the license plate

light bulb

1. Remove

page 6-8.)

cowling

(See

2. Remove the license plate light cov-

er and license plate light lens by

removing the screws.

1. Bulb

4. Insert a new bulb into the socket,

push it in, and then turn it clock-

wise until it stops.

5. Install the license plate light lens

and license plate light cover by in-

stalling the screws.

6. Install the cowling.

1. License plate light lens

2. License plate light cover

3. Screw

3. Remove the defective bulb by

pushing it in and turning it counter-

clockwise.

6-38

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU25880

Troubleshooting

Although Yamaha scooters receive a

thorough inspection before shipment

from the factory, trouble may occur dur-

ing operation. Any problem in the fuel,

compression, or ignition systems, for

example, can cause poor starting and

loss of power.

The following troubleshooting charts

represent quick and easy procedures

for checking these vital systems your-

self. However, should your scooter re-

quire any repair, take it to a Yamaha

dealer, whose skilled technicians have

the necessary tools, experience, and

know-how to service the scooter prop-

erly.

Use only genuine Yamaha replace-

ment parts. Imitation parts may look like

Yamaha parts, but they are often inferi-

or, have a shorter service life and can

lead to expensive repair bills.

6-39

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU42700

EWA10840

Troubleshooting charts

Starting problems or poor engine

performance

WARNING

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

1. Fuel

There is enough fuel.

There is no fuel.

Check the compression.

Check the fuel level in

the fuel tank.

The engine does not start.

Check the compression.

Supply fuel.

2. Compression

There is compression.

Check the ignition.

Operate the electric starter.

Have a Yamaha dealer

check the vehicle.

There is no compression.

3. Ignition

Wipe off with a dry cloth and correct the

spark plug gap, or replace the spark plug.

Wet

Dry

Operate the electric starter.

Remove the spark plug

and check the electrodes.

The engine does not start.

Check the battery.

Have a Yamaha dealer check the vehicle.

4. Battery

The engine turns over

quickly.

The battery is good.

The engine does not start.

Operate the electric starter.

Have a Yamaha dealer

check the vehicle.

The engine turns over

slowly.

Check the battery lead connections,

and charge the battery if necessary.

6-40

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PERIODIC MAINTENANCE AND MINOR REPAIR

Engine overheating

WARNING

EWAT1040

^GDo not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be

blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.

^GPlace a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the de-

tent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the cap

while turning it counterclockwise, and then remove the cap.

There is

leakage.

Have a Yamaha dealer check

and repair the cooling system.

The coolant level is low.

Check the cooling system

for leakage.

There is

no leakage.

Add coolant. (See NOTE.)

Wait until the

engine has cooled.

Check the coolant level in the

reservoir and radiator.

Start the engine. If the engine overheats again, have a

Yamaha dealer check and repair the cooling system.

The coolant level

is OK.

NOTE:

If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant

as soon as possible.

6-41

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SCOOTER CARE AND STORAGE

EAU37833

EAU26091

ucts onto seals, gaskets and wheel

axles. Always rinse the dirt and de-

greaser off with water.

Matte color caution

Care

ECA15192

While 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 if

high-quality components are used. A

rusty exhaust pipe may go unnoticed

on a car, however, it detracts from the

overall appearance of a scooter. Fre-

quent and proper care does not only

comply with the terms of the warranty,

but it will also keep your scooter looking

good, extend its life and optimize its

performance.

CAUTION:

Some models are equipped with

matte colored finished parts. Be

sure to consult a Yamaha dealer for

advice on what products to use be-

fore cleaning the vehicle. Using a

brush, harsh chemical products or

cleaning compounds when cleaning

these parts will scratch or damage

their surface. Wax also should not

be applied to any matte colored fin-

ished parts.

Cleaning

CAUTION:

ECA10781

^GAvoid using strong acidic wheel

cleaners, especially on spoked

wheels. If such products are

used on hard-to-remove dirt, do

not leave the cleaner on the af-

fected area any longer than in-

structed. Also, thoroughly rinse

the area off with water, immedi-

ately dry it, and then apply a cor-

rosion protection spray.

Before cleaning

1. Cover the muffler outlet with a

plastic bag after the engine has

cooled down.

2. Make sure that all caps and covers

as well as all electrical couplers

and connectors, including the

spark plug cap, are tightly in-

stalled.

3. Remove extremely stubborn dirt,

like oil burnt onto the crankcase,

with a degreasing agent and a

brush, but never apply such prod-

^GImproper cleaning can damage

plastic parts such as cowlings,

panels, windshields, headlight

lenses, meter lenses, etc. Use

only a soft, clean cloth or

sponge with mild detergent and

water to clean plastic.

^GDo not use any harsh chemical

products on plastic parts. Be

sure to avoid using cloths or

sponges which have been in

contact with strong or abrasive

7-1

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SCOOTER CARE AND STORAGE

cleaning products, solvent or After normal use

salt.

thinner, fuel (gasoline), rust re- Remove dirt with warm water, a mild

movers or inhibitors, brake flu- detergent, and a soft, clean sponge,

2. Apply a corrosion protection spray

on all metal, including chrome- and

nickel-plated, surfaces to prevent

corrosion.

id, antifreeze or electrolyte.

and then rinse thoroughly with clean

G Do not use high-pressure wash- water. Use a toothbrush or bottlebrush

ers or steam-jet cleaners since for hard-to-reach areas. Stubborn dirt

they cause water seepage and and insects will come off more easily if

deterioration in the following ar- the area is covered with a wet cloth for

eas: seals (of wheel and swing- a few minutes before cleaning.

arm bearings, fork and brakes),

After cleaning

1. Dry the scooter with a chamois or

an absorbing cloth.

2. Use a chrome polish to shine

chrome, aluminum and stain-

less-steel parts, including the ex-

haust system. (Even the thermally

induced discoloring of stain-

less-steel exhaust systems can be

removed through polishing.)

3. To prevent corrosion, it is recom-

mended to apply a corrosion pro-

tection spray on all metal,

including chrome- and nickel-plat-

ed, surfaces.

4. Use spray oil as a universal clean-

er to remove any remaining dirt.

5. Touch up minor paint damage

caused by stones, etc.

6. Wax all painted surfaces.

7. Let the scooter dry completely be-

fore storing or covering it.

electric components (couplers, After riding in the rain, near the sea or

connectors,

switches and lights), breather Since sea salt or salt sprayed on the

hoses and vents. roads during winter are extremely cor-

instruments, on salt-sprayed roads

G For scooters equipped with a rosive in combination with water, carry

windshield: Do not use strong out the following steps after each ride in

cleaners or hard sponges as the rain, near the sea or on

they will cause dulling or salt-sprayed roads.

scratching. Some cleaning com-

pounds for plastic may leave

scratches on the windshield.

Test the product on a small hid-

den part of the windshield to

make sure that it does not leave

any marks. If the windshield is

scratched, use a quality plastic

NOTE:

Salt sprayed on roads in the winter may

remain well into spring.

1. Clean the scooter with cold water

and a mild detergent after the en-

gine has cooled down.

ECA10790

CAUTION:

Do not use warm water since it in-

creases the corrosive action of the

polishing

washing.

compound

after

7-2

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SCOOTER CARE AND STORAGE

EAU36560

EWA10940

what products to use.

Storage

WARNING

^GMake sure that there is no oil or

wax on the brakes or tires. If

necessary, clean the brake

discs and brake linings with a

regular brake disc cleaner or ac-

etone, and wash the tires with

warm water and a mild deter-

gent.

Short-term

Always store your scooter in a cool, dry

place and, if necessary, protect it

against dust with a porous cover.

ECA10820

CAUTION:

^GStoring the scooter in a poorly

ventilated room or covering it

with a tarp, while it is still wet,

will allow water and humidity to

seep in and cause rust.

^GTo prevent corrosion, avoid

damp cellars, stables (because

of the presence of ammonia)

and areas where strong chemi-

cals are stored.

^GBefore operating the scooter

test its braking performance

and cornering behavior.

ECA10800

CAUTION:

^GApply spray oil and wax spar-

ingly and make sure to wipe off

any excess.

^GNever apply oil or wax to any

rubber and plastic parts, but

treat them with a suitable care

product.

^GAvoid using abrasive polishing

compounds as they will wear

away the paint.

Long-term

Before storing your scooter for several

months:

1. Follow all the instructions in the

“Care” section of this chapter.

2. Fill up the fuel tank and add fuel

stabilizer (if available) to prevent

the fuel tank from rusting and the

NOTE:

Consult a Yamaha dealer for advice on

7-3

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SCOOTER CARE AND STORAGE

fuel from deteriorating.

pivoting points of all levers and

3. Perform the following steps to pro-

tect the cylinder, piston rings, etc.

from corrosion.

pedals as well as of the sidestand/

centerstand.

5. Check and, if necessary, correct

the tire air pressure, and then lift

the scooter so that both of its

wheels are off the ground. Alterna-

tively, turn the wheels a little every

month in order to prevent the tires

from becoming degraded in one

spot.

a. Remove the spark plug cap

and spark plug.

b. Pour a teaspoonful of engine oil

into the spark plug bore.

c. Install the spark plug cap onto

the spark plug, and then place

the spark plug on the cylinder

head so that the electrodes are

grounded. (This will limit spark-

ing during the next step.)

6. Cover the muffler outlet with a

plastic bag to prevent moisture

from entering it.

d. Turn the engine over several

times with the starter. (This will

coat the cylinder wall with oil.)

e. Remove the spark plug cap

from the spark plug, and then

install the spark plug and the

7. Remove the battery and fully

charge it. Store it in a cool, dry

place and charge it once a month.

Do not store the battery in an ex-

cessively cold or warm place

[less than 0 °C (30 °F) or more

than 30 °C (90 °F)]. For more in-

formation on storing the battery,

see page 6-33.

spark plug cap.

EWA10950

WARNING

To prevent damage or injury from

sparking, make sure to ground the

spark plug electrodes while turning

the engine over.

NOTE:

Make any necessary repairs before

storing the scooter.

4. Lubricate all control cables and the

7-4

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SPECIFICATIONS

EAU2633K

Lubrication system:

Wet sump

Air filter:

Air filter element:

Engine oil:

Oil-coated paper element

Fuel:

Recommended fuel:

Unleaded gasoline only

Fuel tank capacity:

14.0 L (3.70 US gal) (3.08 Imp.gal)

Dimensions:

Overall length:

2230 mm (87.8 in)

Overall width:

780 mm (30.7 in)

Overall height:

Type:

YAMALUBE 4, SAE10W30 or SAE20W40

0° 10° 30° 50° 70° 90° 110°

130°F

YAMALUBE 4 (10W30)

or SAE 10W30

1380 mm (54.3 in)

Seat height:

760 mm (29.9 in)

Wheelbase:

1565 mm (61.6 in)

Ground clearance:

120 mm (4.72 in)

Minimum turning radius:

2600 mm (102.4 in)

Weight:

With oil and fuel:

212.0 kg (467 lb)

Engine:

Engine type:

Fuel injection:

Throttle body:

Manufacturer:

AISAN

Spark plug (s):

Manufacturer/model:

NGK/CR7E

Spark plug gap:

0.7–0.8 mm (0.028–0.031 in)

Clutch:

Clutch type:

YAMALUBE 4 (20W40)

or SAE 20W40

–20° –10° 0° 10° 20° 30° 40°

50°C

Recommended engine oil grade:

API service SG type or higher, JASO stan-

dard MA

Engine oil quantity:

Without oil filter element replacement:

1.50 L (1.59 US qt) (1.32 Imp.qt)

With oil filter element replacement:

1.70 L (1.80 US qt) (1.50 Imp.qt)

Final transmission oil:

Type:

YAMALUBE 4 (10W30) or SAE10W30 type

SE motor oil

Quantity:

0.25 L (0.26 US qt) (0.22 Imp.qt)

Cooling system:

Dry, centrifugal automatic

Transmission:

Primary reduction system:

Helical gear

Primary reduction ratio:

31/14 (2.214)

Secondary reduction system:

Helical gear

Secondary reduction ratio:

42/16 (2.625)

Liquid cooled 4-stroke, DOHC

Cylinder arrangement:

Forward-inclined single cylinder

Displacement:

395.0 cm

Bore × stroke:

83.0 × 73.0 mm (3.27 × 2.87 in)

Compression ratio:

10.60 :1

Starting system:

Electric starter

Coolant reservoir capacity (up to the maxi-

mum level mark):

0.32 L (0.34 US qt) (0.28 Imp.qt)

Radiator capacity (including all routes):

1.57 L (1.66 US qt) (1.38 Imp.qt)

Transmission type:

V-belt automatic

Operation:

Centrifugal automatic type

8-1

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SPECIFICATIONS

Chassis:

Tire air pressure (measured on cold Rear brake:

Frame type:

Type:

Single disc brake

Operation:

Left hand operation

Recommended fluid:

DOT 4

tires):

Aluminum die-cast and steel tube back-

bone

Caster angle:

27.00 °

Trail:

100.0 mm (3.94 in)

Front tire:

Type:

Tubeless

Size:

120/80-14M/C 58S

Manufacturer/model:

IRC/MB67

Manufacturer/model:

DUNLOP/D305FL

Loading condition:

0–90 kg (0–198 lb)

Front:

200 kPa (29 psi) (2.00 kgf/cm )

Rear:

Front suspension:

Type:

250 kPa (36 psi) (2.50 kgf/cm )

Loading condition:

90–196 kg (198–432 lb)

Front:

200 kPa (29 psi) (2.00 kgf/cm )

Rear:

Telescopic fork

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

250 kPa (36 psi) (2.50 kgf/cm )

120.0 mm (4.72 in)

Front wheel:

Wheel type:

Cast wheel

Rear suspension:

Type:

Unit swing

Rear tire:

Type:

Tubeless

Size:

150/70-13M/C 64S

Manufacturer/model:

IRC/MB67

Manufacturer/model:

DUNLOP/D305L

Loading:

Maximum load:

Rim size:

14 x MT3.00

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

104.0 mm (4.09 in)

Electrical system:

Ignition system:

Transistorized coil ignition (digital)

Charging system:

AC magneto

Battery:

Model:

Rear wheel:

Wheel type:

Cast wheel

Rim size:

13 x MT4.00

Front brake:

Type:

Single disc brake

Operation:

Right hand operation

Recommended fluid:

DOT 4

196 kg (432 lb)

* (Total weight of rider, passenger, cargo

and accessories)

GT9B-4

Voltage, capacity:

12 V, 8.0 Ah

8-2

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SPECIFICATIONS

Radiator fan fuse:

10.0 A

Headlight:

Bulb type:

Fuel injection system fuse:

10.0 A

Backup fuse:

10.0 A

Halogen bulb

Bulb voltage, wattage × quantity:

Headlight:

12 V, 60 W/55.0 W × 2

Tail/brake light:

LED

Front turn signal/position light:

12 V, 21 W/5.0 W × 2

Rear turn signal light:

12 V, 21.0 W × 2

License plate light:

12 V, 5.0 W × 1

Meter lighting:

12 V, 2.0 W × 3

High beam indicator light:

12 V, 1.4 W × 1

Turn signal indicator light:

12 V, 1.4 W × 2

Engine trouble warning light:

12 V, 1.4 W × 1

Fuses:

Main fuse:

40.0 A

Headlight fuse:

20.0 A

Taillight fuse:

10.0 A

Signaling system fuse:

10.0 A

Ignition fuse:

10.0 A

8-3

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CONSUMER INFORMATION

EAU26351

EAU26381

EAU26410

Key identification number

Vehicle identification number

Identification numbers

Record the key identification number,

vehicle identification number and mod-

el label information in the spaces pro-

vided below for assistance when

ordering spare parts from a Yamaha

dealer or for reference in case the vehi-

cle is stolen.

KEY IDENTIFICATION NUMBER:

1. Key identiﬁcation number

1. Vehicle identiﬁcation number

The key identification number is The vehicle identification number is

stamped into the key tag. Record this stamped into the frame.

number in the space provided and use

it for reference when ordering a new

key.

VEHICLE IDENTIFICATION

NUMBER:

NOTE:

The vehicle identification number is

used to identify your vehicle and may

be used to register it with the licensing

authority in your area.

MODEL LABEL INFORMATION:

9-1

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CONSUMER INFORMATION

EAU26500

Model label

1. Model label

The model label is affixed to the inside

of the rear storage compartment. (See

page 3-13.) Record the information on

this label in the space provided. This in-

formation will be needed when ordering

spare parts from a Yamaha dealer.

9-2

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CONSUMER INFORMATION

EAU26551

Reporting safety defects

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately

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 a group

of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems

between you, your dealer, or Yamaha Motor Corporation, U.S.A.

To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-9153); go to http://

www.safercar.gov; or write to: Administrator, NHTSA, 400 Seventh Street, SW., Washington, DC 20590. You can also obtain

other information about motor vehicle safety from http://www.safercar.gov.

9-3

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CONSUMER INFORMATION

EAU26580

Scooter noise regulation

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other

than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new ve-

hicle 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 use of

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 system

Mufﬂer

Exhaust pipe

Silencer

Intake system

Air cleaner case

Air cleaner element

Intake duct

9-4

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CONSUMER INFORMATION

EAU26632

Maintenance record

Copies of work orders and/or receipts for parts purchased and installed on your vehicle will be required to document that

maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder

that maintenance work is required. It is not acceptable proof of maintenance work.

Maintenance

interval

Date of

service

Servicing dealer

name and address

Mileage

Remarks

600 mi

(1000 km) or

1 month

4000 mi

(7000 km) or

6 months

8000 mi

(13000 km) or

12 months

12000 mi

(19000 km) or

18 months

16000 mi

(25000 km) or

24 months

20000 mi

(31000 km) or

30 months

24000 mi

(37000 km) or

36 months

28000 mi

(43000 km) or

42 months

9-5

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CONSUMER INFORMATION

Maintenance

interval

Date of

service

Servicing dealer

name and address

Mileage

Remarks

32000 mi

(49000 km) or

48 months

36000 mi

(55000 km) or

54 months

40000 mi

(61000 km) or

60 months

9-6

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CONSUMER INFORMATION

EAU26663

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

WARRANTY

Yamaha Motor Corporation, U.S.A. hereby warrants that

new Yamaha motorcycles will be free from defects in

material and workmanship for the period of time stated

herein, subject to certain stated limitations.

THE CUSTOMER’S RESPONSIBILITY under this

warranty shall be to:

1. Operate and maintain the motorcycle as specified in

the appropriate Owner’s Manual, and

2. Give notice to an authorized Yamaha motorcycle

dealer of any and all apparent defects within ten (10)

days after discovery, and make the machine available

at that time for inspection and repairs at such dealer’s

place of business.

Engine

Displacement

Under 50cc

Period

6,000 km (3,750 miles)

or five years, whichever occurs first

THE PERIOD OF WARRANTY for Yamaha motorcycles

originally equipped with headlight, stoplight, and turn

signals shall be one (1) year from the date of purchase,

with no mileage limitation.

50cc to 169cc

170cc to 279cc

280cc and over

12,000 km (7,465 miles)

or five years whichever occurs first

18,000 km (11,185 miles)

or five years, whichever occurs first

MODELS EXCLUDED FROM WARRANTY include

those used for non-Yamaha-authorized renting, leasing

or other commercial purposes, and TZ models.

WARRANTY TRANSFER: To transfer the warranty from

the original purchaser to any subsequent purchaser, it is

imperative that the machine be inspected and registered

for warranty by an authorized Yamaha motorcycle dealer.

In order for this warranty to remain in effect, this

inspection and registration must take place within ten

(10) days after transfer. An inspection and registration fee

will be charged for this service.

30,000 km (18,641 miles)

or five years, whichever occurs first

DURING THE PERIOD OF WARRANTY, any authorized

Yamaha motorcycle dealer will, free of charge, repair or

replace any part adjudged defective by Yamaha due to

faulty workmanship or material from the factory. Parts used

in warranty repairs will be warranted for the balance of the

product’s warranty period. All parts replaced under

warranty become property of Yamaha Motor Corporation,

U.S.A.

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO

OTHER WARRANTY OF ANY KIND, EXPRESSED OR

IMPLIED.

MERCHANTABILITY

PARTICULAR PURPOSE WHICH EXCEED THE

OBLIGATIONS AND TIME LIMITS STATED IN THIS

WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA

MOTOR CORPORATION, U.S.A. AND EXCLUDED

FROM THIS WARRANTY.

ALL

IMPLIED

AND

WARRANTIES

FITNESS FOR

EMISSION CONTROL SYSTEM WARRANTY:

Yamaha Motor Corporation, U.S.A. also warrants to the

ultimate purchaser and each subsequent purchaser of

each Yamaha motorcycle covered by this warranty with a

displacement of 50cc or greater, that the vehicle is

designed, built, and equipped so as to conform at the

time of sale with all U.S. emissions standards applicable

at the time of manufacture and that it is free from defects

in materials and workmanship which would cause it not

to meet these standards within the period listed

immediately below. Failures other than those resulting

from defects in material or workmanship, which arise

solely as a result of owner abuse and/or lack of proper

maintenance, are not covered by this warranty.

GENERAL EXCLUSIONS from this warranty shall

include any failures caused by:

a) Competition or racing use.

b) Installation of parts or accessories that are not

qualitatively equivalent to genuine Yamaha parts.

c) Abnormal strain, neglect, or abuse.

d) Lack of proper maintenance.

SOME STATES DO NOT ALLOW LIMITATIONS ON

HOW LONG AN IMPLIED WARRANTY LASTS, SO THE

ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO

EXCLUDED FROM THIS WARRANTY ARE ANY

INCIDENTAL OR CONSEQUENTIAL DAMAGES

INCLUDING LOSS OF USE. SOME STATES DO NOT

ALLOW THE EXCLUSION OR LIMITATION OF

INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO

THE ABOVE EXCLUSION MAY NOT APPLY TOYOU.

e) Accident or collision damage.

f) Modification to original parts.

SPECIFIC EXCLUSIONS from this warranty shall

include parts replaced due to normal wear or routine

maintenance.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL

RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS

WHICH VARY FROM STATE TO STATE.

YAMAHA MOTOR CORPORATION, U.S.A.

P.O. Box 6555

Cypress, California 90630

9-7

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CONSUMER INFORMATION

WARRANTY QUESTIONS AND ANSWERS

CUSTOMER SERVICE

What costs are my responsibility during the warranty period?

The customer’s responsibility includes all costs of normal maintenance services,

non-warranty repairs, accident and collision damages, and oil, oil filters, air filters,

spark plugs, and brake shoes.

If your machine requires warranty service, you must take it to any authorized Yamaha

motorcycle dealer within the continental United States. Be sure to bring your warranty

registration card or other valid proof of the original date of purchase. If a question or

problem arises regarding the warranty, first contact the owner of the dealership. Since

all warranty matters are handled at the dealer level, this person is in the best position to

help you. IF you are still not satisfied and require additional assistance, please write to:

What are some examples of “abnormal” strain, neglect, or abuse?

These terms are general and overlap each other in areas. Specific examples

include: Running the machine out of oil, sustained high rpm, full-throttle, operating

the machine with a broken or damaged part which causes another part to fail,

damage or failure due to improper or careless transportation and/or tie-down. If

you have any specific questions on operation or maintenance, please contact your

dealer for advice.

YAMAHA MOTOR CORPORATION, U.S.A.

CUSTOMER RELATIONS DEPARTMENT

P.O. Box 6555

Cypress, California 90630

When contacting Yamaha Motor Corporation, U.S.A., don’t forget to include any

important information such as names, addresses, model, V.I.N. (frame number),

dates, and receipts.

Does the warranty cover incidental costs such as towing or transportation due to

a failure?

No. The warranty is limited to repair of the machine itself.

CHANGE OF ADDRESS

May I perform any or all of the recommended maintenance shown in the Owner’s

Manual instead of having the dealer do them?

Yes, if you are a qualified mechanic and follow the procedures specified in the

Owner’s and Service Manual. We do recommend, however, that items requiring

special tools or equipment be done by a Yamaha motorcycle dealer.

The federal government requires each manufacturer of a motor vehicle to maintain a

complete, up-to-date list of all first purchasers against the possibility of a safety-

related defect and recall. This list is compiled from the purchase registrations sent to

Yamaha Motor Corporation, U.S.A. by the selling dealer at the time of your purchase.

Will the warranty be void or cancelled if I do not operate or maintain my new

motorcycle exactly as specified in the Owner’s Manual?

No. The warranty on a new motorcycle cannot be “voided” or “cancelled.” However,

if a particular failure is caused by operation or maintenance other than as

described in the Owner’s Manual, that failure may not be covered under

warranty.

If you should move after you have purchased your new motorcycle, please advise us

of your new address by sending a postcard listing your motorcycle model name, V.I.N.

(frame number), dealer number (or dealer’s name) as it is shown on your warranty

card, your name and new mailing address. Mail to:

YAMAHA MOTOR CORPORATION, U.S.A.

P.O. Box 6555

What responsibility does my dealer have under this warranty?

Each Yamaha motorcycle dealer is expected to:

Cypress, California 90630

Attention: Warranty Department

Completely set up every new machine before sale.

Explain the operation, maintenance, and warranty requirements to your

satisfaction at the time of sale, and upon your request at any later date.

Each Yamaha motorcycle dealer is held responsible for his setup, service and

warranty repair work.

This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration

record in accordance with federal law.

Is the warranty transferable to second owners?

Yes. The remainder of the existing warranty can be transferred upon request. The

unit has to be inspected and re-registered by an authorized Yamaha motorcycle

dealer for the policy to remain effective.

9-8

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CONSUMER INFORMATION

EAU26750

YAMAHA EXTENDED SERVICE (Y.E.S.)

Keep your Yamaha protected even after your warranty

expires with genuine Yamaha Extended Service (Y.E.S.).

In addition, Travel and Recreation Interruption Protection

(TRIP) is included at no extra cost. TRIP gives you up to

$150 reimbursement per occurrence for any reasonable

expenses you incur because your Yamaha needs

covered service: replacement vehicle rental, emergency

towing, phone calls, even food and lodging when you are

away from home. This superb coverage goes into effect

when you purchase Y.E.S., so it applies to any warranty

repairs as well as covered repairs during your entire

Y.E.S. plan period.

Y.E.S. is designed and administered by Yamaha Motor

Corporation to provide maximum owner satisfaction. You

get uninterrupted factory-backed coverage for extra

peace of mind.

Y.E.S. is flexible. You choose the plan that’s right for

you: 12 months, 24 months, 36 months or, on certain

models, even 48 months beyond your warranty period.

Y.E.S. coverage is honored at any authorized Yamaha

dealer nationwide.

Y.E.S. is designed and administered by the same

Yamaha people who handle your warranty – and it

shows in the comprehensive coverage benefits. There

are no mileage limitations. Coverage isn’t limited to

“moving parts” or the “drive train” like many other plans.

And Y.E.S. covers manufacturing defects just like the

warranty. See the sample contract at your Yamaha

dealer to see how comforting uninterrupted factory-

backed protection can be.

Y.E.S. coverage is transferable to a new owner if you

sell or trade-in. That can make your Yamaha much more

valuable!

This excellent Y.E.S. plan coverage is only available to

Yamaha owners like you, and only while your Yamaha is still

within the Yamaha Limited Warranty period. So visit your

authorized Yamaha dealer to get all the facts. He can show

you how easy it is to protect your investment with Yamaha

Extended Service.

You don’t have to pay anything for covered repairs.

There’s no deductible to pay, and repairs aren’t

“pro-rated.” You don’t have any “out-of-pocket” expenses

for covered repairs.

9-9

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CONSUMER INFORMATION

We urge you to act now. You’ll get the excellent benefits of

TRIP coverage right away, and you’ll rest easy knowing

you’ll have strong factory-backed protection even after your

Yamaha Limited Warranty expires.

A special note:

If visiting your dealer isn’t convenient, contact Yamaha with

your Primary ID number (your frame number). We’ll be

happy to help you get the Y.E.S. coverage you need.

Yamaha Service Marketing

P.O. Box 6555

Cypress, CA 90630

1-(866)-YES-EXTD (1-866-937-3983)

9-10

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INDEX

Front fork, checking.................................6-31

Fuel .........................................................3-10

Fuel tank cap.............................................3-9

Fuses, replacing......................................6-34

Acceleration and deceleration ...................5-2

Rear brake lock lever ................................ 3-8

Rear brake lock lever cable, adjusting .... 6-27

Rider seat, adjusting ............................... 3-13

Accessories and replacement parts ........6-26

Air filter elements and check hoses and V-belt

case air filter element ............................6-20

Handlebar switches...................................3-7

Headlight bulb, replacing.........................6-36

High beam indicator light...........................3-2

Horn switch................................................3-7

Safe-riding points ...................................... 1-4

Safety defects, reporting ........................... 9-3

Safety information ..................................... 1-1

Seats....................................................... 3-11

Shock absorber assemblies, adjusting.... 3-15

Sidestand ................................................ 3-16

Spark plug, checking............................... 6-12

Specifications............................................ 8-1

Speedometer............................................. 3-2

Starting off................................................. 5-2

Starting the engine.................................... 5-1

Start switch................................................ 3-7

Steering, checking................................... 6-32

Storage...................................................... 7-3

Storage compartments............................ 3-13

Battery .....................................................6-33

Brake fluid, changing...............................6-29

Brake fluid level, checking.......................6-28

Brake lever, front .......................................3-8

Brake lever, rear........................................3-8

Brake levers, lubricating ..........................6-30

Braking ......................................................5-2

Identification numbers ...............................9-1

Ignition circuit cut-off system...................3-16

Indicator and warning lights.......................3-2

Cables, checking and lubricating.............6-30

Canister ...................................................6-14

Care...........................................................7-1

Catalytic converter...................................3-11

Centerstand and sidestand, checking and

lubricating..............................................6-31

Coolant ....................................................6-18

Cowlings and panels, removing and

Key identification number..........................9-1

Labels, location of .....................................1-6

License plate light bulb, replacing ...........6-38

Main switch/steering lock ..........................3-1

Maintenance and lubrication, periodic.......6-4

Maintenance, emission control system .....6-3

Maintenance, periodic ...............................6-1

Maintenance record...................................9-5

Matte color, caution...................................7-1

Model label................................................9-2

Multi-function display.................................3-3

Tachometer............................................... 3-3

Tail/brake light......................................... 6-36

Throttle cable free play, checking ........... 6-23

Throttle grip and cable, checking and

installing ..................................................6-8

Dimmer switch...........................................3-7

lubricating ............................................. 6-30

Tires ........................................................ 6-23

Tool kit....................................................... 6-2

Troubleshooting ...................................... 6-39

Troubleshooting charts............................ 6-40

Turn signal indicator lights ........................ 3-2

Turn signal light bulb (front), replacing.... 6-36

Turn signal light bulb (rear), replacing..... 6-37

Turn signal switch ..................................... 3-7

Engine break-in .........................................5-3

Engine oil and oil filter element................6-14

Engine stop switch.....................................3-7

Engine trouble warning light ......................3-2

Noise regulation ........................................9-4

Parking ......................................................5-4

Part locations.............................................2-1

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

Final transmission oil...............................6-17

Front and rear brake lever free play ........6-26

Front and rear brake pads, checking.......6-28

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INDEX

Valve clearance ...................................... 6-23

Vehicle identification number.................... 9-1

Warranty, extended................................... 9-9

Warranty, limited....................................... 9-7

Wheel bearings, checking....................... 6-33

Wheels.................................................... 6-25

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YAMAHA MOTOR CO., LTD.

PRINTED ON RECYCLED PAPER

PRINTED IN JAPAN

2007.6–0.4×1 !

(E)

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