Page 1
OWNER’S MANUAL
YJ50RT
YJ50RAT
LIT-11626-18-26
5LY-28199-15
Page 2
Page 3
INTRODUCTION
EAU10070
Congratulations on your purchase of the Yamaha YJ50R. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability 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.
Page 4
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
CAUTION:
Failure to follow WARNING instructions could result in severe injury or death to the
scooter operator, a bystander, or a person inspecting or repairing the scooter.
A CAUTION indicates special precautions that must be taken to avoid damage to
the scooter.
EAU35820
NOTE:
A NOTE provides key information to make procedures easier or clearer.
NOTE:
●
This manual should be considered a permanent part of this scooter and should remain with it even if the scooter is subsequently sold.
●
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most
current product information available at the time of printing, there may be minor discrepancies between your scooter and
this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
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 UNTIL 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 CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS SCOOTER.
Page 5
IMPORTANT MANUAL INFORMATION
AFFIX DEALER
LABEL HERE
YJ50RT/YJ50RAT
OWNER’S MANUAL
©2004 by Yamaha Motor Corporation, U.S.A.
1st edition, April 2004
All rights reserved.
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-11626-18-26
EAU10192
Page 6
TABLE OF CONTENTS
SAFETY INFORMATION
Further safe-riding points .................1-4
Location of important labels .............1-6
DESCRIPTION
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS
Main switch/steering lock .................3-1
Indicator and warning lights .............3-2
Speedometer unit ............................3-3
Fuel gauge .......................................3-3
Handlebar switches .........................3-3
Front brake lever .............................3-4
Rear brake lever ..............................3-5
Fuel tank cap ...................................3-5
Fuel ..................................................3-6
2-stroke engine oil ...........................3-7
Kickstarter ........................................3-8
Seat .................................................3-8
Helmet holder ..................................3-8
Storage compartment ......................3-9
Carrier ............................................3-10
PRE-OPERATION CHECKS
Pre-operation check list ...................4-2
...................................2-1
........................................3-1
...................1-1
...............4-1
OPERATION AND IMPORTANT
RIDING POINTS
Starting and warming up a cold
engine .......................................... 5-1
Starting off ....................................... 5-2
Acceleration and deceleration ......... 5-2
Braking ............................................ 5-3
Engine break-in ...............................5-4
Parking ............................................ 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR
Periodic maintenance and
lubrication chart ........................... 6-2
Removing and installing the
panel ............................................ 6-5
Checking the spark plug .................. 6-5
Final transmission oil ....................... 6-7
Cleaning the air filter sponge
material ........................................ 6-8
Adjusting the carburetor ..................6-9
Adjusting the throttle cable free
play ............................................ 6-10
Tires .............................................. 6-10
Adjusting the front and rear brake
lever free play ............................6-12
Checking the front and rear brake
shoes ......................................... 6-13
Checking and lubricating the
throttle grip and cable ................6-13
Adjusting the Autolube pump ........6-14
.................................. 5-1
.................................. 6-1
Lubricating the front and rear
brake levers ............................... 6-14
Battery ........................................... 6-14
Replacing the fuse ........................ 6-16
Troubleshooting ............................ 6-16
Troubleshooting chart ................... 6-17
SCOOTER CARE AND STORAGE
Care ................................................ 7-1
Storage ........................................... 7-3
SPECIFICATIONS
CONSUMER INFORMATION
Identification numbers ..................... 9-1
Reporting safety defects ................. 9-3
Scooter noise regulation ................. 9-4
YAMAHA MOTOR CORPORATION,
U.S.A. RIVA LIMITED
WARRANTY ................................ 9-5
YAMAHA EXTENDED SERVICE
(Y.E.S.) ........................................ 9-7
............................. 8-1
.... 7-1
............. 9-1
Page 7
SAFETY INFORMATION
EAU10240
SCOOTERS ARE SINGLE TRACK
VEHICLES. THEIR SAFE USE AND
OPERATION ARE DEPENDENT
UPON THE USE OF PROPER
RIDING TECHNIQUES AS WELL AS
THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD
KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS
SCOOTER.
HE OR SHE SHOULD:
●
OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
SCOOTER OPERATION.
●
OBSERVE THE WARNINGS
AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
●
OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.
●
OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED
BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECES-
SARY BY MECHANICAL CONDITIONS.
Safe riding
●
Always make pre-operation
checks. Careful checks may help
prevent an accident.
●
This scooter is designed to carry
the operator only. No passengers.
●
The failure of motorists to detect
and recognize scooters in traffic is
the predominating cause of automobile/scooter accidents. Many
accidents have been caused by an
automobile driver who did not see
the scooter. Making yourself conspicuous appears to be very effective in reducing the chance of this
type of accident.
●
Therefore:
●
Wear a brightly colored jacket.
●
Use extra caution when approaching and passing through
intersections, since intersections are the most likely places
for scooter accidents to occur.
●
Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.
●
Many accidents involve inexperienced operators. In fact, many operators who have been involved in
accidents do not even have a current driver’s license.
●
Make sure that you are qualified
and that you only lend your
scooter to other qualified operators.
●
Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
●
We recommend that you practice riding your scooter where
there is no traffic until you have
become thoroughly familiar with
the scooter and all of its controls.
●
Many accidents have been caused
by error of the scooter operator. A
typical error made by the operator
is veering wide on a turn due to
EXCESSIVE SPEED or undercornering (insufficient lean angle for
1
1-1
Page 8
SAFETY INFORMATION
the speed).
●
Always obey the speed limit and
never travel faster than warranted by road and traffic conditions.
1
●
Always signal before turning or
changing lanes. Make sure that
other motorists can see you.
●
The posture of the operator is important for proper control. The operator should keep both hands on
the handlebar and both feet on the
footboard during operation to
maintain control of the scooter.
●
Never ride under the influence of
alcohol or other drugs.
●
This scooter is designed for
on-road use only. It is not suitable
for off-road use.
Protective apparel
The majority of fatalities from scooter
accidents are the result of head injuries. The use of a safety helmet is the
single most critical factor in the prevention or reduction of head injuries.
●
Always wear an approved helmet.
●
Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
●
The use of a jacket, substantial
shoes, trousers, gloves, etc., is effective in preventing or reducing
abrasions or lacerations.
●
Never wear loose-fitting clothes,
otherwise they could catch on the
control levers or wheels and cause
injury or an accident.
●
Never touch the engine or exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear protective clothing that covers your legs,
ankles, and feet.
Modifications
Modifications made to this scooter not
approved by Yamaha, or the removal of
original equipment, may render the
scooter unsafe for use and may cause
severe personal injury. Modifications
may also make your scooter illegal to
use.
Loading and accessories
Adding accessories or cargo to your
scooter can adversely affect stability
and handling if the weight distribution of
the scooter is changed. To avoid the
possibility of an accident, use extreme
caution when adding cargo or accessories to your scooter. Use extra care
when riding a scooter that has added
cargo or accessories. Here are some
general guidelines to follow if loading
cargo or adding accessories to your
scooter:
Loading
The total weight of the operator, accessories and cargo must not exceed the
maximum load limit of 75 kg (165 lb).
When loading within this weight limit,
keep the following in mind:
●
Cargo and accessory weight
should be kept as low and close to
the scooter as possible. Make sure
to distribute the weight as evenly
as possible on both sides of the
scooter to minimize imbalance or
instability.
1-2
Page 9
●
Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely
attached to the scooter before
riding. Check accessory mounts
and cargo restraints frequently.
●
Never attach any large or heavy
items to the handlebar, front fork,
or front fender. Such items can
create unstable handling or a slow
steering response.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this scooter. Since Yamaha cannot test
all other accessories that may be available, you must personally be responsible for the proper selection, installation
and use of non-Yamaha accessories.
Use extreme caution when selecting
and installing any accessories.
Keep the following guidelines in mind,
as well as those provided under “Loading” when mounting accessories.
●
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 suspension travel, steering travel or
control operation, or obscure lights
or reflectors.
●
Accessories fitted to the handlebar or the front fork area can
create instability due to improper
weight distribution or aerodynamic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
●
Bulky or large accessories may
seriously affect the stability of
the scooter due to aerodynamic
effects. Wind may attempt to lift
the scooter, or the scooter may
become unstable in cross
winds. These accessories may
also cause instability when
passing or being passed by
SAFETY INFORMATION
large vehicles.
●
Certain accessories can displace the operator from his or
her normal riding position. This
improper position limits the freedom of movement of the operator and may limit control ability,
therefore, such accessories are
not recommended.
●
Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the
scooter’s electrical system an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
Gasoline and exhaust gas
●
GASOLINE IS HIGHLY FLAMMABLE:
●
Always turn the engine off when
refueling.
●
Take care not to spill any gasoline on the engine or exhaust
system when refueling.
●
Never refuel while smoking or in
the vicinity of an open flame.
1
1-3
Page 10
SAFETY INFORMATION
●
Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poisonous and may cause loss of
1
consciousness and death within a
short time. Always operate your
scooter in an area that has adequate ventilation.
●
Always turn the engine off before
●
If you should swallow any gasoline, inhale a lot of gasoline vapor,
or allow gasoline to get in your
eyes, see your doctor immediately. If any gasoline spills on your
skin or clothing, immediately wash
the affected area with soap and
water and change your clothes.
Further safe-riding points
●
Make sure to signal clearly when
making turns.
EAU10350
leaving the scooter unattended
and remove the key from the main
switch. When parking the scooter,
note the following:
●
The engine and exhaust system
may be hot, therefore, park the
scooter in a place where pedestrians or children are not likely to
touch these hot areas.
●
Do not park the scooter on a
slope or soft ground, otherwise it
may fall over.
●
Do not park the scooter near a
flammable source (e.g., a kerosene heater, or near an open
flame), otherwise it could catch
fire.
●
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.
1-4
Page 11
●
Slow down as you approach a cor-
ner or turn. Once you have com-
pleted a turn, accelerate slowly.
●
Be careful when passing parked
cars. A driver might not see you
and open a door in your path.
●
Railroad crossings, streetcar rails,
iron plates on road construction
sites, and manhole covers 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.
●
The brake lining could get wet
when you wash the scooter. After
washing the scooter, check the
brakes before riding.
●
Always wear a helmet, gloves,
trousers (tapered around the cuff
and ankle so they do not flap), and
a bright colored jacket.
●
Do not carry too much luggage on
the scooter. An overloaded scoot-
er is unstable. Use a strong cord to
secure any luggage to the carriers.
SAFETY INFORMATION
A loose load will affect the stability
of the scooter and could divert
your attention from the road. (See
page 1-1.)
1
1-5
Page 12
SAFETY INFORMATION
Location of important labels
Please read the following important labels carefully before operating this vehicle.
1
EAU10381
5
2
3
4
1
1-6
Page 13
SAFETY INFORMATION
1
BEFORE YOU OPERATE THIS VEHICLE, READ
THE OWNER’S MANUAL AND ALL LABELS.
NEVER CARRY A PASSENGER. you increase your
risk of losing control if you carry a passenger.
ALWAYS WEAR AN APPROVED MOTORCYCLE
HELMET, eye protection, and protective clothing.
2
LOAD LIMIT
WARNING
5 kg {11 lbs}
3LD-24877-A0
3
Improper loading can cause loss of control.
Read owner’s manual for proper loading.
WARNING
4
WARNING
NEVER sit on carrier.
CARRIER LOAD LIMIT.
{ }
7 lbs
3 k g
5LY-24875-00
3JJ-20446-A1
3SL-2118K-A0
5
Cold tire normal pressure should be set as
follows.
FRONT :
150 kPa,{1.50 kgf/cm2}, 22 psi
:REAR
175 kPa,{1.75 kgf/cm2}, 25 psi
1
5LY-21668-A0
1-7
Page 14
DESCRIPTION
Left view
1
2
3
4
5
6
7
8
1. Front wheel
2. Front turn signal light
3. Rear turn signal light
9
4. Rear wheel
5. Kickstarter (page 3-8)
6. Air filter sponge material (page 6-8)
7. Battery (page 6-14)
12 3
67
45
EAU10410
2-1
Page 15
Right view
DESCRIPTION
EAU10420
1
1. Tail/brake light
2. Carrier (page 3-10)
3. 2-stroke engine oil tank cap cover (page 3-7)
4. Seat (page 3-8)
5. Headlight
6. Spark plug (page 6-5)
7. Centerstand
8. Muffler
3
87
6
542
2
3
4
5
6
7
8
9
2-2
Page 16
DESCRIPTION
Controls and instruments
EAU10430
1
2
3
4
5
6
7
8
1. Rear brake lever (page 3-5)
2. Left handlebar switches (page 3-3)
3. Fuel gauge (page 3-3)
9
4. Speedometer unit (page 3-3)
5. Main switch/steering lock (page 3-1)
6. Right handlebar switches (page 3-3)
7. Front brake lever (page 3-4)
8. Throttle grip (page 6-10)
3
56
4
7
8
1
2
2-3
Page 17
INSTRUMENT AND CONTROL FUNCTIONS
1
2
EAU10460
Main switch/steering lock
OFF
ON
LOCK
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.
EAU10610
ON
All electrical circuits are supplied with
power, the taillight and meter lighting
come on, and the engine can be started. The key cannot be removed.
NOTE:
The headlight comes on as soon as the
engine is started.
EAU10660
OFF
All electrical systems are off. The key
can be removed.
EAU10670
The 2-stroke engine oil level warning
light should come on. (See page 3-2.)
EAU10680
LOCK
The steering is locked, and all electrical
systems are off. The key can be removed.
To lock the steering
OFF(PUSH)
LOCK
Turn the handlebars all the way to the
left.
1. Push the key in from the “OFF” po-
sition, and then turn it to “LOCK”
while still pushing it.
2. Remove the key.
To unlock the steering
1. Push.
2. Turn.
Push the key in, and then turn it to
“OFF” while still pushing it.
EWA10060
WARNING
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
loss of control or an accident. Make
sure that the vehicle is stopped before turning the key to “OFF” or
2
3
4
5
6
7
8
9
3-1
Page 18
INSTRUMENT AND CONTROL FUNCTIONS
1
2
3
4
5
6
7
8
9
“LOCK”.
EAU11001
Indicator and warning lights
123
1. 2-stroke engine oil level warning light
“”
2. Turn signal indicator light “”
3. High beam indicator light “”
EAU11020
Turn signal indicator light “”
This indicator light flashes 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.
EAU32440
2-stroke engine oil level warning
light “”
The warning light comes on when the
key is in the “” position or when the
engine oil level in the 2-stroke engine
oil tank is low during operation. If the
warning light comes on during operation, stop immediately and fill the oil
tank with YAMALUBE 2 or an equivalent 2-stroke engine oil. The warning
light should go off after the 2-stroke engine oil tank has been refilled.
NOTE:
If the 2-stroke engine oil level warning
light does not come on when the key is
in the “ON” position or does not go off
after the 2-stroke engine oil tank has
been refilled, have a Yamaha dealer
check the electrical circuit.
ECA12720
CAUTION:
Do not operate the vehicle until you
know that the 2-stroke engine oil level is sufficient.
3-2
Page 19
INSTRUMENT AND CONTROL FUNCTIONS
1
2
3
EAU11630
Speedometer unit
2
1
1. Tripmeter reset knob
2. Speedometer
3. Odometer
4. Tripmeter
The speedometer unit is equipped with
a speedometer, an odometer and a
tripmeter. The speedometer shows
riding speed. The odometer shows the
total distance traveled. The tripmeter
shows the distance traveled since it
was last set to zero with the reset knob.
The tripmeter can be used to estimate
the distance that can be traveled with a
full tank of fuel. This information will enable you to plan future fuel stops.
3
4
EAU12140
Fuel gauge
E
1
1. Fuel gauge
The fuel gauge indicates the amount of
fuel in the fuel tank. The needle moves
towards “E” (Empty) as the fuel level
decreases. When the needle reaches
“E”, refuel as soon as possible.
NOTE:
Do not allow the fuel tank to empty itself
completely.
F
3-3
Handlebar switches
Left
1. Dimmer switch “ / ”
2. Turn signal switch “ / ”
3. Horn switch “”
EAU12343
2
3
4
5
6
7
8
9
Page 20
INSTRUMENT AND CONTROL FUNCTIONS
1
Right
1
1
2
3
1. Engine stop switch “ / ”
4
2. Start switch “”
5
Dimmer switch “ / ”
Set this switch to “” for the high
6
beam and to “” for the low beam.
7
Turn signal switch “ / ”
To signal a right-hand turn, push this
8
switch to “”. To signal a left-hand
turn, push this switch to “”. When re-
9
leased, the switch returns to the center
position. To cancel the turn signal
lights, push the switch in after it has returned to the center position.
2
EAU12400
EAU12460
EAU12500
Horn switch “”
Press this switch to sound the horn.
EAU12660
Engine stop switch “ / ”
Set this switch to “” before starting
the engine. Set this switch to “” to
stop the engine in case of an emergency, such as when the vehicle overturns
or when the throttle cable is stuck.
EAU12710
Start switch “”
Push this switch to crank the engine
with the starter.
ECA10050
CAUTION:
See page 5-1 for starting instructions prior to starting the engine.
EAU12900
Front brake lever
1. Front brake lever
The front brake lever is located on the
right handlebar grip. To apply the front
brake, pull this lever toward the handlebar grip.
3-4
Page 21
INSTRUMENT AND CONTROL FUNCTIONS
1
EAU12950
Rear brake lever
1
1. Rear brake lever
The rear brake lever is located on the
left handlebar grip. To apply the rear
brake, pull this lever toward the handlebar grip.
EAU32482
Fuel tank cap
2
1
1. Fuel tank cap lock cover
2. Unlock.
To remove the fuel tank cap
Slide the lock cover open, insert the key
into the lock, and then turn it 1/4 turn
clockwise. The lock will be released
and the fuel tank cap can be removed.
3-5
To install the fuel tank cap
1. Match marks
1. Insert the fuel tank cap into the
tank opening with the key inserted
in the lock and with the marks on
the cap and tank aligned.
2. Turn the key counterclockwise to
the original position, remove it, and
then close the lock cover.
NOTE:
The fuel tank cap cannot be installed
unless the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly installed and locked.
EWA10130
WARNING
Make sure that the fuel tank cap is
2
3
4
5
6
7
8
9
Page 22
INSTRUMENT AND CONTROL FUNCTIONS
properly installed before riding.
1
2
3
4
5
6
7
8
9
EAU13210
Fuel
2
1. Fuel tank filler tube
2. Fuel level
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
WARNING
Do not overfill the fuel tank, oth-
●
erwise it may overflow when the
fuel warms up and expands.
Avoid spilling fuel on the hot en-
●
gine.
CAUTION:
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
1
EWA10880
ECA10070
3-6
fuel may deteriorate painted surfaces or plastic parts.
EAU32410
Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
6.0 L (1.59 US gal) (1.32 Imp.gal)
Your Yamaha engine has been designed to use regular unleaded gasoline 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 premium unleaded fuel. Use of unleaded fuel
will extend spark plug life and reduce
maintenance costs.
Gasohol
There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing
ethanol can be used if the ethanol content does not exceed 10%. Gasohol
containing methanol is not recommended by Yamaha because it can
Page 23
INSTRUMENT AND CONTROL FUNCTIONS
cause damage to the fuel system or vehicle performance problems.
EAU13540
2-stroke engine oil
Make sure that there is sufficient oil in
the 2-stroke engine oil tank. If necessary, add the recommended 2-stroke
engine oil as follows.
1
3
2
1. 2-stroke engine oil tank cap
2. 2-stroke engine oil tank cap cover
3. Unlock.
4. Lock.
1. Remove the 2-stroke engine oil
tank cap cover as shown.
2. Remove the 2-stroke engine oil
tank cap and add the recommended oil.
4
Recommended oil:
See page 8-1.
Oil quantity:
1.4 L (1.48 US qt) (1.23 Imp.qt)
3. Install the 2-stroke engine oil tank
cap and tank cap cover.
NOTE:
Make sure that the 2-stroke engine oil
tank cap is properly installed.
2
3
4
5
6
7
8
9
3-7
Page 24
INSTRUMENT AND CONTROL FUNCTIONS
1
Kickstarter
1
2
1
3
4
1. Kickstarter
To start the engine, fold out the kick-
5
starter lever, move it down lightly with
your foot until the gears engage, and
6
then push it down smoothly but forcefully.
7
8
9
EAU13680
EAU13890
Seat
To open the seat
1. Insert the key in the lock, and then
turn it as shown.
1
1. Open.
2. Fold the seat up.
To close the seat
1. Fold the seat down, and then push
it down to lock it in place.
2. Remove the key.
NOTE:
Make sure that the seat is properly secured before riding.
EAU14300
Helmet holder
1. Helmet holder
The helmet holder is located under the
seat.
To secure a helmet to the helmet
holder
1. Open the seat. (See page 3-8.)
2. Attach the helmet to the helmet
holder, and then securely close the
seat.
EWA10160
WARNING
Never ride with a helmet attached to
the helmet holder, since the helmet
may hit objects, causing loss of control and possibly an accident.
3-8
Page 25
INSTRUMENT AND CONTROL FUNCTIONS
To release the helmet from the helmet holder
Open the seat, remove the helmet from
the helmet holder, and then close the
seat.
EAU14510
Storage compartment
1
1. Storage compartment
There is a storage compartment under
the seat. (See page 3-8.)
WARNING
Do not exceed the load limit of
●
5 kg (11 lb) for the storage compartment.
Do not exceed the maximum
●
load of 75 kg (165 lb) for the vehicle.
CAUTION:
Keep the following points in mind
when using the storage compart-
EWA10960
ECA10080
ment.
●
Since the storage compartment
accumulates heat when exposed to the sun, do not store
anything susceptible to heat inside it.
●
To avoid humidity from spreading through the storage compartment, wrap wet articles in a
plastic bag before storing them
in the compartment.
●
Since the storage compartment
may get wet while the scooter is
being washed, wrap any articles
stored in the compartment in a
plastic bag.
●
Do not keep anything valuable
or breakable in the storage compartment.
To store a helmet in the storage compartment, place the helmet upside-down with the front facing forward.
NOTE:
●
Some helmets cannot be stored in
the storage compartment because
2
3
4
5
6
7
8
9
3-9
Page 26
INSTRUMENT AND CONTROL FUNCTIONS
of their size or shape.
●
Do not leave your scooter unattended with the seat open.
Carrier
1
EAU15110
1
2
3
4
5
6
7
1. Carrier
WARNING
Do not exceed the load limit of
●
3 kg (7 lb) for the carrier.
Do not exceed the maximum
●
load of 75 kg (165 lb) for the ve-
EWA10170
hicle.
8
9
3-10
Page 27
PRE-OPERATION CHECKS
EAU15591
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
NOTE:
Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short
time; and the added safety it assures is more than worth the time involved.
EWA11150
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the vehicle.
2
3
4
5
6
7
8
4-1
9
Page 28
PRE-OPERATION CHECKS
Pre-operation check list
ITEM CHECKS PAGE
●
Check fuel level in fuel tank.
Fuel
1
2
2-stroke engine oil
Final transmission oil
3
Front brake
4
5
Rear brake
6
Throttle grip
7
8
Wheels and tires
9
Brake levers
Centerstand
Chassis fasteners
●
Refuel if necessary.
●
Check fuel line for leakage.
●
Check oil level in oil tank.
●
If necessary, add recommended oil to specified level.
●
Check vehicle for oil leakage.
●
Check vehicle for oil leakage. 6-7
●
Check operation.
Lubricate cable if necessary.
●
Check lever free play.
●
Adjust if necessary.
●
Check operation.
●
●
Lubricate cable if necessary.
Check lever free play.
●
Adjust if necessary.
●
Make sure that operation is smooth.
●
Check cable free play.
●
If necessary, have Yamaha dealer adjust cable free play and lubricate cable
●
and grip housing.
Check for damage.
●
Check tire condition and tread depth.
●
Check air pressure.
●
Correct if necessary.
●
Make sure that operation is smooth.
●
Lubricate lever pivoting points if necessary.
●
Make sure that operation is smooth.
●
Lubricate pivot if necessary.
●
Make sure that all nuts, bolts and screws are properly tightened.
●
Tighten if necessary.
●
EAU15602
3-6
3-7
6-12, 6-13
6-12, 6-13
6-10, 6-13
6-10
6-14
—
—
4-2
Page 29
ITEM CHECKS PAGE
Instruments, lights, signals
and switches
●
Check operation.
●
Correct if necessary.
PRE-OPERATION CHECKS
—
2
3
4
5
6
7
8
4-3
9
Page 30
OPERATION AND IMPORTANT RIDING POINTS
2
1
EAU15980
EWA10870
WARNING
Become thoroughly familiar
●
1
with all operating controls and
their functions before riding.
2
Consult a Yamaha dealer regarding any control or function
Starting and warming up a cold engine
CAUTION:
See page 5-4 for engine break-in instructions prior to operating the vehicle for the first time.
EAU16582
ECA10250
circuit.
3. Close the throttle completely.
that you do not thoroughly un-
3
4
5
6
7
8
9
derstand.
Never 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 consciousness and death within a
short time. Always make sure
that there is adequate ventilation.
For safety, always start the en-
●
gine with the centerstand down.
OFF
ON
LOCK
1. Set the engine stop switch to “”.
2. Turn the key to “”, and when the
2-stroke engine oil level warning
light comes on, turn the key to
“ON”.
ECA11580
CAUTION:
If the 2-stroke engine oil level warning light does not come on, have a
Yamaha dealer check the electrical
5-1
1. Start switch “”
2. Kickstarter
4. Start the engine by pushing the
start switch or by pushing the kickstarter lever down, while applying
the front or rear brake.
NOTE:
If the engine fails to start by pushing the
start switch, release the switch, wait a
few seconds, and then try again. Each
starting attempt should be as short as
possible to preserve the battery. Do not
crank the engine more than 5 seconds
on any one attempt. If the engine does
Page 31
OPERATION AND IMPORTANT RIDING POINTS
(a)
(b)
not start with the starter motor, try using
the kickstarter.
ECA11130
CAUTION:
For maximum engine life, always
warm the engine up before starting
off. Never accelerate hard when the
engine is cold!
EAU16770
Starting off
NOTE:
Before starting off, allow the engine to
warm up.
1. While pulling the rear brake lever
with your left hand and holding the
carrier with your right hand, push
the scooter off the centerstand.
2. Sit astride the seat, and then adjust the rear view mirrors.
3. Switch the turn signal on.
4. Check for oncoming traffic, and
then slowly turn the throttle grip (on
the right) in order to take off.
5. Switch the turn signal off.
EAU16780
Acceleration and deceleration
The speed can be adjusted by opening
and closing the throttle. To increase the
speed, turn the throttle grip in direction
(a). To reduce the speed, turn the throttle grip in direction (b).
2
3
4
5
6
7
8
9
5-2
Page 32
OPERATION AND IMPORTANT RIDING POINTS
Braking
1. Close the throttle completely.
2. Apply both front and rear brakes
1
2
3
4
5
6
7
8
9
simultaneously while gradually increasing the pressure.
Front
EAU16791
Rear
WARNING
Avoid braking hard or suddenly
●
(especially when leaning over to
one side), otherwise the scooter
may skid or overturn.
Railroad crossings, streetcar
●
rails, iron plates on road construction sites, and manhole
covers become extremely slippery when wet. Therefore, slow
down when approaching such
areas and cross them with caution.
Keep in mind that braking on a
●
wet road is much more difficult.
●
Ride slowly down a hill, as brak-
ing downhill can be very difficult.
EWA10300
5-3
Page 33
OPERATION AND IMPORTANT RIDING POINTS
EAU16830
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1000 km (600 mi). For
this reason, you should read the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1000 km (600 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throttle operation or any condition that might
result in engine overheating must be
avoided.
EAU17160
0–150 km (0–90 mi)
●
Avoid prolonged operation above
1/3 throttle.
●
After every hour of operation, stop
the engine, and then let it cool for
five to ten minutes.
●
Vary the engine speed from time to
time. Do not operate the engine at
one set throttle position.
150–500 km (90–300 mi)
Avoid prolonged operation above 1/2
throttle.
ECA11450
CAUTION:
After 500 km (300 mi) of operation,
be sure to replace the final transmission oil.
500–1000 km (300–600 mi)
Avoid prolonged operation above 3/4
throttle.
1000 km (600 mi) and beyond
Avoid prolonged full-throttle operation.
Vary the engine speed occasionally.
ECA10270
CAUTION:
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
EAU17212
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10310
WARNING
Since the engine and exhaust
●
system can become very hot,
2
3
4
5
6
7
8
9
5-4
Page 34
OPERATION AND IMPORTANT RIDING POINTS
park in a place where pedestrians or children are not likely to
touch them.
●
1
2
3
4
5
6
7
8
Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn.
ECA10380
CAUTION:
Never park in an area where there
are fire hazards such as grass or
other flammable materials.
9
5-5
Page 35
EAU17291
Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the
safest and most efficient condition possible. The most important points of vehicle inspection, adjustment, and
lubrication are explained on the following pages.
EWA10320
WARNING
If you are not familiar with maintenance work, have a Yamaha dealer
do it for you.
PERIODIC MAINTENANCE AND MINOR REPAIR
2
3
4
5
6
7
8
6-1
9
Page 36
PERIODIC MAINTENANCE AND MINOR REPAIR
Periodic maintenance and lubrication chart
NOTE:
From 6000 mi (9000 km) or 18 months, repeat the maintenance intervals starting from 2000 mi (3000 km) or 6 months.
●
1
2
3
4
5
6
7
8
9
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
●
skills.
No. ITEM CHECKS AND MAINTENANCE JOBS
●
1*
Fuel line
2
Spark plug
3*
Idle speed
4
Air filter element
5*
Autolube pump
6*
Final transmission oil
7
Front brake
Check fuel and vacuum hoses for cracks or damage.
●
Replace if necessary.
●
Check condition.
●
Adjust gap and clean.
●
Replace if necessary.
●
Check and adjust engine idle speed.
●
Clean with solvent.
●
Replace if necessary.
●
Check operation.
●
Correct if necessary.
●
Bleed.
●
Check oil leakage.
●
Correct if necessary.
●
Change at initial 300 mi (500 km) or 1 month and thereafter
every 8000 mi (12000 km) or 24 months. (Ride scooter a few
minutes before draining oil.)
●
Check operation.
●
Adjust cable and replace brake shoes if necessary.
EAU35560
INITIAL EVERY
300 mi
(500 km)
or
1 month
2000 mi
(3000 km)
or
6 months
4000 mi
(6000 km)
or
12 months
√√
√√√
√√
√√
√√
√√√
√√
6-2
Page 37
PERIODIC MAINTENANCE AND MINOR REPAIR
No. ITEM CHECKS AND MAINTENANCE JOBS
●
8
Rear brake
9*
Wheels
*
Tires
10
*
Wheel bearings
11
*
Steering bearings
12
*
Shock absorber assembly
13
*
V-belt
14
*
Chassis fasteners
15
*
Control and meter cables
16
Throttle grip housing and
*
17
cable
*
Centerstand pivot
18
Check operation.
●
Adjust cable and replace brake shoes if necessary.
●
Check runout and for damage.
●
Replace if necessary.
●
Check tread depth and for damage.
●
Replace if necessary.
Check air pressure.
●
Correct if necessary.
●
Check bearing assemblies for looseness.
●
Moderately repack with lithium-soap-based grease.
●
●
Check bearing assemblies for looseness.
Moderately repack with lithium-soap-based grease every 8000
●
mi (12000 km) or 24 months.
Check operation and for oil leakage.
●
Replace if necessary.
●
Check damage and wear.
●
Replace every 6000 mi (9000 km).
●
Make sure that all nuts, bolts and screws are properly tight-
●
ened.
Apply Yamaha chain and cable lube or engine oil 10W-30 thor-
●
oughly.
Check operation and free play.
●
Adjust the throttle cable free play if necessary.
●
Lubricate the throttle grip housing and cable.
●
Check operation.
●
Apply lithium-soap-based grease (all-purpose grease) lightly.
●
INITIAL EVERY
300 mi
(500 km)
or
1 month
2000 mi
(3000 km)
or
6 months
4000 mi
(6000 km)
or
12 months
√√
√√
√√
√√
√√√
√√
√
√√√
√√√
√√
√√√
2
3
4
5
6
7
8
9
6-3
Page 38
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
1
2
3
4
5
6
7
8
EAU18690
9
6-4
Page 39
PERIODIC MAINTENANCE AND MINOR REPAIR
1
Removing and installing the
panel
The panel shown needs to be removed
to perform some of the maintenance
jobs described in this chapter. Refer to
this section each time the panel needs
to be removed and installed.
1
1. Panel A
Panel A
To remove the panel
1. Open the seat. (See page 3-8.)
2. Remove the screws, and then pull
the panel off as shown.
EAU18751
EAU19481
1
1. Screw
1
2
1. Panel A
2. Screw
To install the panel
Place the panel in the original position,
and then install the screws.
EAU19611
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 maintenance and lubrication chart. In addition,
the condition of the spark plug can reveal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
1. Spark plug cap
2. Remove the spark plug as shown,
with a spark plug wrench available
at a Yamaha dealer.
2
3
4
5
6
7
8
9
6-5
Page 40
PERIODIC MAINTENANCE AND MINOR REPAIR
1
1
2
3
1. Spark plug wrench
4
To check the spark plug
1. Check that the porcelain insulator
5
6
7
8
9
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
NOTE:
If the spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the vehicle.
2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
Specified spark plug:
NGK/BPR7HS
To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if necessary, adjust the gap to specification.
1
1. Spark plug gap
Spark plug gap:
0.6–0.7 mm (0.024–0.028 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.
3. Install the spark plug with the
spark plug wrench, and then tighten it to the specified torque.
Tightening torque:
Spark plug:
20 Nm (2.0 m·kgf, 14 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 specified torque as soon as possible.
4. Install the spark plug cap.
6-6
Page 41
EAU20060
Final transmission oil
The final transmission case must be
checked for oil leakage before each
ride. If any leakage is found, have a
Yamaha dealer check and repair the
scooter. In addition, the final transmission oil must be changed as follows at
the intervals specified in the periodic
maintenance and lubrication chart.
1. Start the engine, warm it up by
riding the scooter for several minutes, and then stop the engine.
2. Place the scooter on the centerstand.
3. Place an oil pan under the final
transmission case to collect the
used oil.
4. Remove the oil filler cap and drain
bolt to drain the oil from the final
transmission case.
PERIODIC MAINTENANCE AND MINOR REPAIR
Recommended final transmission oil:
1
2
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.
Tightening torque:
Final transmission oil drain bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten the
oil filler cap.
See page 8-1.
Oil quantity:
0.10 L (0.11 US qt) (0.09 Imp.qt)
EWA11310
WARNING
●
Make sure that no foreign material enters the final transmission
case.
Make sure that no oil gets on the
●
tire or wheel.
7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
2
3
4
5
6
7
8
9
6-7
Page 42
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
1
EAU21102
Cleaning the air filter sponge
material
The air filter sponge material should be
1
cleaned at the intervals specified in the
periodic maintenance and lubrication
chart. Clean the air filter sponge mate-
2
rial more frequently if you are riding in
unusually wet or dusty areas.
3
1. Remove panel A. (See page 6-5.)
2. Remove the air filter case cover by
4
5
6
7
8
9
removing the screws, then pulling
the cover off while squeezing the
clamp.
1
2
1. Air filter case cover
2. Screw
CAUTION:
Make sure that no foreign material
enters the carburetor intake.
3. Pull the air filter sponge material
out, clean it with solvent, and then
squeeze the remaining solvent
out.
6-8
1. Clamp
2. Carburetor intake
ECA11320
1. Air filter sponge material
EWA10430
WARNING
Use only a dedicated parts cleaning
solvent. To avoid the risk of fire or
explosion, do not use gasoline or
Page 43
PERIODIC MAINTENANCE AND MINOR REPAIR
solvents with a low flash point.
ECA11460
CAUTION:
To avoid damaging the air filter
sponge material, handle it gently
and carefully, and do not twist it.
12
3
4. Apply oil of the recommended type
to the entire surface of the air filter
sponge material, and then
squeeze the excess oil out.
NOTE:
The air filter sponge material should be
wet but not dripping.
4
5. Insert the air filter sponge material
into the air filter case.
ECA11470
CAUTION:
Make sure that the air filter
●
sponge material is properly
seated in the air filter case.
The engine should never be op-
●
erated without the air filter
sponge material installed, otherwise the piston and/or cylinder may become excessively
worn.
6. Install the air filter case cover by
placing it in the original position,
fastening it with the clamp, then installing the screws.
7. Install the panel.
EAU21300
Adjusting the carburetor
The carburetor is an important part of
the engine and requires very sophisticated adjustment. Therefore, all carburetor adjustments should be left to a
Yamaha dealer, who has the necessary professional knowledge and experience.
2
3
4
5
6
7
8
9
Recommended oil:
Yamaha foam air filter oil or other
quality air filter oil
6-9
Page 44
PERIODIC MAINTENANCE AND MINOR REPAIR
Adjusting the throttle cable free play
1
2
3
4
1. Throttle cable free play
5
The throttle cable free play should measure 1.5–3.5 mm (0.06–0.14 in) at the
6
throttle grip. Periodically check the
throttle cable free play and, if neces-
7
sary, have a Yamaha dealer adjust it.
8
9
1
EAU21380
EAU21911
Tires
To maximize the performance, durability, and safe operation of your scooter,
note the following points regarding the
specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
6-10
EWA10540
WARNING
Because loading has an enormous
impact on the handling, braking,
performance and safety characteristics of your scooter, you should
keep the following precautions in
mind.
NEVER OVERLOAD THE
●
Page 45
PERIODIC MAINTENANCE AND MINOR REPAIR
SCOOTER! Operation of an
overloaded scooter may result
in tire damage, loss of control,
or severe injury. Make sure that
the total weight of rider, cargo,
and accessories does not exceed the specified maximum
load for the vehicle.
●
Improper tire air pressure greatly affects tire life and handling.
●
If the tire air pressure is too
high, shocks from the road will
not be dampened but instead be
transmitted to the frame and
handlebars, which impairs
riding comfort. In addition, the
scooter will be unstable in
curves.
●
If the tire air pressure is too low,
the tires will be damaged and
the tire life shortened. In addition, the tires could slip off the
wheel rims during braking,
which could result in tube damage. The scooter could also eas-
ily turn over in a curve.
Tire air pressure* (measured on cold
tires):
Front:
150 kPa (22 psi) (1.50 kgf/cm
Rear:
175 kPa (25 psi) (1.75 kgf/cm2)
2
)
Tire inspection
3
1
1. Tire sidewall
2. Tire wear indicator
3. Tire tread depth
Always check the tires before operating
the scooter. If a tire tread shows crosswise lines (minimum tread depth), if the
tire has a nail or glass fragments in it, or
if the sidewall is cracked, contact a
Yamaha dealer immediately and have
2
the tire replaced.
Minimum tire tread depth (front and
rear):
1.0 mm (0.04 in)
Tire information
This scooter is equipped with panel
wheels and tubeless tires.
Front tire:
Size:
80/90-10 35J
Manufacturer/model:
IRC/MB38
CHENG SHIN/C-922
Rear tire:
Size:
80/90-10 35J
Manufacturer/model:
IRC/MB38
CHENG SHIN/C-922
EWA10580
WARNING
It 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.
●
The replacement of all wheel-
2
3
4
5
6
7
8
9
6-11
Page 46
PERIODIC MAINTENANCE AND MINOR REPAIR
1
1
(a)
(b)
(a)
(b)
and brake-related parts, including the tires, should be left to a
Yamaha dealer, who has the
EAU22150
Adjusting the front and rear
brake lever free play
brake lever free play, turn the adjusting
nut in direction (b).
necessary professional knowl-
1
edge and experience.
1
1
2
3
4
1. Brake lever free play adjusting nut
5
6
7
8
9
1. Brake lever free play
The front and rear brake lever free play
should be measured at the positions as
shown.
Front brake lever free play:
10.0–20.0 mm (0.39–0.79 in)
Rear brake lever free play:
10.0–20.0 mm (0.39–0.79 in)
Periodically check the front and rear
brake lever free play and, if necessary,
WARNING
If proper adjustment cannot be obtained as described, have a Yamaha
dealer make this adjustment.
EWA10650
adjust them as follows.
To increase the brake lever free play,
turn the adjusting nut at the brake shoe
plate in direction (a). To decrease the
6-12
Page 47
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU22361
Checking the front and rear brake shoes
2
1
1. Brake shoe wear indicator
2. Brake shoe wear limit line
The front and rear brake shoes must be
checked for wear at the intervals specified in the periodic maintenance and
lubrication chart. Each brake is provided with a wear indicator, which allows
you to check the brake shoe wear without having to disassemble the brake.
To check the brake shoe wear, check
the position of the wear indicator while
applying the brake. If a brake shoe has
worn to the point that the wear indicator
reaches the wear limit line, have a
1
2
Yamaha dealer replace the brake
shoes as a set.
EAU23110
Checking and lubricating the throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addition, the cable should be lubricated or
replaced at the intervals specified in the
periodic maintenance chart.
2
3
4
5
6
7
8
9
6-13
Page 48
PERIODIC MAINTENANCE AND MINOR REPAIR
Adjusting the Autolube pump
The Autolube pump is a vital and sophisticated component of the engine,
1
which must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
2
chart.
3
4
5
6
7
8
9
EAU23120
EAU23170
Lubricating the front and rear
brake levers
The pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic maintenance and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
EAU23431
Battery
This model is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There is
no need to check the electrolyte or to
add distilled water.
WARNING
●
Electrolyte is poisonous and
dangerous since it contains sulfuric acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and always shield your eyes when
working near batteries. In case
of contact, administer the following FIRST AID.
●
EXTERNAL: Flush with plenty
of water.
●
INTERNAL: Drink large quantities of water or milk and immediately call a physician.
●
EYES: Flush with water for 15
minutes and seek prompt
medical attention.
Batteries produce explosive hy-
●
EWA10760
6-14
Page 49
PERIODIC MAINTENANCE AND MINOR REPAIR
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and provide sufficient ventilation when
charging it in an enclosed
space.
●
KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF
CHILDREN.
To remove the battery
1
2
1. Battery box cover
2. Screw
1. Remove panel A. (See page 6-5.)
2. Remove the battery box cover by
removing the screw.
3. Pull the battery out from the battery box, and then disconnect the
battery coupler.
To install the battery
1
2
1. Battery coupler
2. Battery
1. Connect the battery coupler, and
then place the battery in the original position.
2. Install the battery box cover by installing the screw.
3. Install the panel.
To charge the battery
Have a Yamaha dealer charge the battery 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
electrical accessories.
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 installation.
CAUTION:
Always keep the battery
●
charged. Storing a discharged
battery can cause permanent
battery damage.
To charge a sealed-type (MF)
●
battery, a special (constant-voltage) 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 charger, have a Yamaha dealer
charge your battery.
ECA10630
2
3
4
5
6
7
8
9
6-15
Page 50
PERIODIC MAINTENANCE AND MINOR REPAIR
Replacing the fuse
1
1
2
3
4
1. Fuse
The fuse is located inside the battery
5
lead coupler.
If the fuse is blown, replace it as fol-
6
lows.
1. Turn the key to “OFF” and turn off
7
8
9
all electrical circuits.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
Specified fuse:
7.5 A
EAU23450
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.
3. Turn the key to “ON” and turn on
the electrical circuits to check if the
devices operate.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAU25860
Troubleshooting
Although Yamaha scooters receive a
thorough inspection before shipment
from the factory, trouble may occur during operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems yourself. However, should your scooter require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the scooter properly.
Use only genuine Yamaha replacement parts. Imitation parts may look like
Yamaha parts, but they are often inferior, have a shorter service life and can
lead to expensive repair bills.
ECA10640
CAUTION:
Do not use a fuse of a higher amper-
6-16
Page 51
PERIODIC MAINTENANCE AND MINOR REPAIR
Troubleshooting chart
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
EAU25901
EWA10840
1. Fuel
Check the fuel level in
the fuel tank.
2. Compression
Operate the electric starter.
3. Ignition
Remove the spark plug
and check the electrodes.
4. Battery
Operate the electric starter.
There is enough fuel.
There is no fuel.
There is compression.
There is no compression.
Wet
Dry
The engine turns over
quickly.
The engine turns over
slowly.
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
Check the compression.
Supply fuel.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
The battery is good.
Check the battery lead connections,
and charge the battery if necessary.
The engine does not start.
Check the compression.
6-17
Open the throttle halfway and operate
the electric starter.
The engine does not start.
Check the battery.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
2
3
4
5
6
7
8
9
Page 52
SCOOTER CARE AND STORAGE
Care
While the open design of a scooter reveals the attractiveness of the technol-
1
ogy, it also makes it more vulnerable.
Rust and corrosion can develop even if
high-quality components are used. A
2
rusty exhaust pipe may go unnoticed
on a car, however, it detracts from the
3
overall appearance of a scooter. Frequent and proper care does not only
4
comply with the terms of the warranty,
but it will also keep your scooter looking
5
good, extend its life and optimize its
performance.
6
Before cleaning
1. Cover the muffler outlet with a
7
8
9
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
EAU26090
brush, but never apply such products onto seals, gaskets and wheel
axles. Always rinse the dirt and degreaser off with water.
Cleaning
CAUTION:
Avoid using strong acidic wheel
●
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse
the area off with water, immediately dry it, and then apply a corrosion protection spray.
Improper cleaning can damage
●
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.
Do not use any harsh chemical
●
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
7-1
ECA10780
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
●
Do not use high-pressure washers or steam-jet cleaners since
they cause water seepage and
deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.
●
For scooters equipped with a
windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning compounds for plastic may leave
scratches on the windshield.
Test the product on a small hidden part of the windshield to
make sure that it does not leave
any marks. If the windshield is
Page 53
SCOOTER CARE AND STORAGE
scratched, use a quality plastic
polishing compound after
washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on the
roads during winter are extremely corrosive in combination with water, carry
out the following steps after each ride in
the rain, near the sea or on
salt-sprayed roads.
NOTE:
Salt sprayed on roads in the winter may
remain well into spring.
1. Clean the scooter with cold water
and a mild detergent after the en-
gine has cooled down.
ECA10790
CAUTION:
Do not use warm water since it increases the corrosive action of the
salt.
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After cleaning
1. Dry the scooter with a chamois or
an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stainless-steel parts, including the exhaust system. (Even the thermally
induced discoloring of stainless-steel exhaust systems can be
removed through polishing.)
3. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal,
including chrome- and nickel-plated, 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 before storing or covering it.
EWA10940
WARNING
●
Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or acetone, and wash the tires with
warm water and a mild detergent.
Before operating the scooter
●
test its braking performance
and cornering behavior.
ECA10800
CAUTION:
Apply spray oil and wax spar-
●
ingly and make sure to wipe off
any excess.
Never apply oil or wax to any
●
rubber and plastic parts, but
2
3
4
5
6
7
8
9
7-2
Page 54
SCOOTER CARE AND STORAGE
treat them with a suitable care
product.
●
Avoid using abrasive polishing
compounds as they will wear
1
2
away the paint.
NOTE:
Consult a Yamaha dealer for advice on
what products to use.
3
4
5
6
7
8
9
EAU26300
Storage
Short-term
Always store your scooter in a cool, dry
place and, if necessary, protect it
against dust with a porous cover.
CAUTION:
Storing the scooter in a poorly
●
ventilated room or covering it
with a tarp, while it is still wet,
will allow water and humidity to
seep in and cause rust.
To prevent corrosion, avoid
●
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemicals are stored.
Long-term
Before storing your scooter for several
months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
7-3
ECA10820
fuel tank.
3. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
4. Perform the following steps to protect the cylinder, piston rings, etc.
from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit sparking during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap.
Page 55
SCOOTER CARE AND STORAGE
EWA10950
WARNING
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
5. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
6. Check and, if necessary, correct
the tire air pressure, and then lift
the scooter so that both of its
wheels are off the ground. Alternatively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
7. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
8. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an excessively cold or warm place
[less than 0 °C (30 °F) or more
than 30 °C (90 °F)]. For more information on storing the battery,
see page 6-14.
NOTE:
Make any necessary repairs before
storing the scooter.
2
3
4
5
6
7
8
9
7-4
Page 56
SPECIFICATIONS
Dimensions:
1
2
3
4
Weight:
5
Engine:
6
7
8
9
Overall length:
1630 mm (64.2 in)
Overall width:
630 mm (24.8 in)
Overall height:
1030 mm (40.6 in)
Seat height:
715 mm (28.1 in)
Wheelbase:
1150 mm (45.3 in)
Ground clearance:
85 mm (3.35 in)
With oil and fuel:
74.0 kg (163 lb)
Engine type:
Air cooled 2-stroke
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
49.0 cm3 (2.99 cu.in)
Bore × stroke:
40.0 × 39.2 mm (1.57 × 1.54 in)
Compression ratio:
7.30 :1
Starting system:
Electric starter and kickstarter
Lubrication system:
Separate lubrication (Yamaha autolube)
EAU26337
Engine oil:
Type:
YAMALUBE 2-cycle oil or 2-stroke engine
oil
Quantity:
1.4 L (1.48 US qt) (1.23 Imp.qt)
Final transmission oil:
Type:
YAMALUBE 4 (10W30) or SAE10W30 type
SE motor oil
Quantity:
0.10 L (0.11 US qt) (0.09 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:
Unleaded gasoline only
Fuel tank capacity:
6.0 L (1.59 US gal) (1.32 Imp.gal)
Carburetor:
Manufacturer:
TEIKEI
Type x quantity:
Y14P x 1
Spark plug(s):
Manufacturer/model:
NGK/BPR7HS
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Clutch:
Clutch type:
Dry, centrifugal automatic
Transmission:
Primary reduction system:
Helical gear
Primary reduction ratio:
48/13 (3.692)
Secondary reduction system:
Spur gear
Secondary reduction ratio:
42/13 (3.230)
Transmission type:
V-belt automatic
Operation:
Centrifugal automatic type
Chassis:
Frame type:
Steel tube underbone
Caster angle:
25.00 °
Trail:
71.0 mm (2.80 in)
Front tire:
Type:
Tubeless
Size:
80/90-10 35J
Manufacturer/model:
IRC/MB38
Manufacturer/model:
CHENG SHIN/C-922
8-1
Page 57
SPECIFICATIONS
Rear tire:
Type:
Tubeless
Size:
80/90-10 35J
Manufacturer/model:
IRC/MB38
Manufacturer/model:
CHENG SHIN/C-922
Loading:
Maximum load:
75 kg (165 lb)
* (Total weight of rider, passenger, cargo
and accessories)
Tire air pressure (measured on cold
tires):
Front:
150 kPa (22 psi) (1.50 kgf/cm
Rear:
175 kPa (25 psi) (1.75 kgf/cm2)
2
)
Front wheel:
Wheel type:
Panel wheel
Rim size:
10x2.15
Rear wheel:
Wheel type:
Panel wheel
Rim size:
10x2.15
Front brake:
Type:
Drum brake
Operation:
Right hand operation
Rear brake:
Type:
Drum brake
Operation:
Left hand operation
Front suspension:
Type:
Bottom-link fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
52.0 mm (2.05 in)
Rear suspension:
Type:
Unit swing
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
48.0 mm (1.89 in)
Electrical system:
Ignition system:
DC. C.D.I.
Charging system:
A.C. magneto
Battery:
Model:
GT4B-5
Voltage, capacity:
12 V, 2.5 Ah
Headlight:
Bulb type:
Halogen bulb
Bulb voltage, wattage x quantity:
Headlight:
12 V, 35 W/35.0 W × 1
Tail/brake light:
12 V, 8.0/27.0 W × 1
Front turn signal light:
12 V, 10.0 W × 2
Rear turn signal light:
12 V, 10.0 W × 2
Meter lighting:
12 V, 1.7 W × 1
Meter lighting (fuel meter):
14 V, 1.4 W × 1
High beam indicator light:
12 V, 1.7 W × 1
Oil level warning light:
12 V, 1.7 W × 1
Turn signal indicator light:
14 V, 3.0 W × 1
Fuse:
Fuse:
7.5 A
2
3
4
5
6
7
8
9
8-2
Page 58
CONSUMER INFORMATION
1
Identification numbers
Record the key identification number,
vehicle identification number and mod-
1
el label information in the spaces provided below for assistance when
ordering spare parts from a Yamaha
2
dealer or for reference in case the vehicle is stolen.
3
KEY IDENTIFICATION NUMBER:
4
5
VEHICLE IDENTIFICATION NUM-
6
BER:
7
8
MODEL LABEL INFORMATION:
9
EAU26351
EAU26390
Key identification number
1
1. Key identification number
The key identification number is
stamped into the key. Record this number in the space provided and use it for
reference when ordering a new key.
EAU26410
Vehicle identification number
1. Vehicle identification number
The vehicle identification number is
stamped into the frame.
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.
9-1
Page 59
Model label
CONSUMER INFORMATION
EAUT1440
2
1
3
1. Model label
The model label is affixed to the inside
of the storage compartment. (See
page 3-9.) Record the information on
this label in the space provided. This information will be needed when ordering
spare parts from a Yamaha dealer.
4
5
6
7
8
9
9-2
Page 60
CONSUMER INFORMATION
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,
1
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.
2
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.
area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information
3
about motor vehicle safety from the Hotline.
4
5
6
7
8
EAU26550
9
9-3
Page 61
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 vehicle 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
●
2
3
4
5
6
7
8
9-4
9
Page 62
CONSUMER INFORMATION
YAMAHA MOTOR CORPORATION, U.S.A. RIVA LIMITED WARRANTY
1
2
3
4
5
6
7
8
EAU26680
9
9-5
Page 63
CONSUMER INFORMATION
2
3
4
5
6
7
8
9-6
9
Page 64
CONSUMER INFORMATION
YAMAHA EXTENDED SERVICE (Y.E.S.)
EAU26750
Keep your Yamaha protected even after your warranty
expires with genuine Yamaha Extended Service (Y.E.S.).
1
2
3
4
5
6
7
8
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. 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 factorybacked protection can be.
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.
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. coverage is honored at any authorized Yamaha
dealer nationwide.
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.
9
9-7
Page 65
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)
CONSUMER INFORMATION
2
3
4
5
6
7
8
9-8
9
Page 66
INDEX
2
2-stroke engine oil..................................... 3-7
A
Acceleration and deceleration................... 5-2
Air filter sponge material, cleaning............ 6-8
Autolube pump, adjusting ....................... 6-14
B
Battery..................................................... 6-14
Brake lever, front....................................... 3-4
Brake lever, rear ....................................... 3-5
Brake levers, lubricating.......................... 6-14
Brake shoes, checking............................ 6-13
Braking...................................................... 5-3
C
Carburetor,adjusting ................................. 6-9
Care .......................................................... 7-1
Carrier ..................................................... 3-10
D
Dimmer switch .......................................... 3-4
E
Engine break-in......................................... 5-4
Engine stop switch .................................... 3-4
F
Final transmission oil ................................ 6-7
Front and rear brake lever free play,
adjusting ............................................... 6-12
Fuel ........................................................... 3-6
Fuel gauge ................................................ 3-3
Fuel tank cap ............................................ 3-5
Fuse, replacing ....................................... 6-16
H
Handlebar switches................................... 3-3
Helmet holder............................................ 3-8
High beam indicator light ........................... 3-2
Horn switch................................................3-4
I
Identification numbers................................9-1
Indicator and warning lights.......................3-2
K
Key identification number ..........................9-1
Kickstarter..................................................3-8
L
Labels, location of......................................1-6
M
Main switch/steering lock...........................3-1
Maintenance and lubrication, periodic .......6-2
Model label ................................................9-2
N
Noise regulation.........................................9-4
P
Panel, removing and installing...................6-5
Parking.......................................................5-4
Part locations.............................................2-1
Pre-operation check list ............................. 4-2
S
Safe-riding points.......................................1-4
Safety defects, reporting............................9-3
Safety information......................................1-1
Seat ...........................................................3-8
Spark plug, checking .................................6-5
Specifications.............................................8-1
Speedometer unit ......................................3-3
Starting and warming up a cold engine .....5-1
Starting off .................................................5-2
Start switch ................................................ 3-4
Storage ......................................................7-3
Storage compartment ................................3-9
T
Throttle cable free play, adjusting ...........6-10
Throttle grip and cable, checking and
lubricating.............................................. 6-13
Tires ........................................................6-10
Troubleshooting....................................... 6-16
Troubleshooting chart.............................. 6-17
Turn signal indicator light ..........................3-2
Turn signal switch...................................... 3-4
Two-stroke engine oil level warning
light.......................................................... 3-2
V
Vehicle identification number ....................9-1
W
Warranty, extended ................................... 9-7
Warranty, limited .......................................9-5
Page 67
OWNER’S MANUAL
PRINTED ON RECYCLED PAPER
YAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN
PRINTED IN JAPAN
2002·5–0.6×1(E)
2004.5–0.7×1 !
!
(E)
Loading...