Page 49 of 100
6-7
1
1
1. Screw (×3)
To install the panelPlace the panel in the original posi-
tion, and then install the screws.Panel B
To remove the panel
Remove the panel screws, and then
pull outward on the areas shown.
To install the panelPlace the panel in the original posi-
tion, and then install the screws.
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
1
1. Screw (×4)Panels C and E
To remove one of the panelsPull the floorboard mat off, and then
remove the panel screws.
To install the panelPlace the panel in the original posi-
tion, install the screws, and then
place the floorboard mat back.
5GJ-9-EV 5/26/01 11:04 AM Page 48
Page 50 of 100
6-8
1
12
Panel F
To remove the panelRemove the panel screws.
To install the panel1. Place the panel in the original
position, and then install the
screws.Cowling B
To remove the cowling
1. Remove panels C and E.
2. Remove the cowling screws and
bolts.
3. Unhook the cowling from the
holder at the bottom.
4. Unhook the front of the cowling
by pushing it up, and then pull
the cowling out.
1. Screw (×2) 1. Bolt (×2)
2. Screw (×2)
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
2
1
2
Cowling A
To remove the cowling1. Remove the rear view mirrors by
removing the nuts.
2. Remove the cowling screws.
To install the cowling1. Place the cowling in the original
position, and then install the
screws.
2. Install the rear view mirrors by
installing the nuts.1. Screw (×2)
2. Nut (×4)
5GJ-9-EV 5/26/01 11:04 AM Page 49
Page 51 of 100
EAU03816
Checking the spark plugsThe spark plugs are important engine
components, which are easy to
check. Since heat and deposits will
cause any spark plug to slowly erode,
the spark plugs should be removed
and checked in accordance with the
periodic maintenance and lubrication
chart. In addition, the condition of the
spark plugs can reveal the condition
of the engine.
6-9
1
2
1. Bolt (×2)
2. Screw (×3)
To install the cowling1. Place the cowling in the original
position, and then install the
screws and bolts.
2. Install panels C and E.Cowling C
To remove the cowling
1. Remove the cowling bolts.
2. Remove the battery cover by
removing the screws.
3. Pull the cowling off.
To install the cowling1. Install the battery cover by
installing the screws.
2. Place the cowling in the original
position, and then install the
bolts.
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
95GJ-9-EV 5/26/01 11:04 AM Page 50
Page 52 of 100
6-10
1
3. Remove the spark plug cap.1. Spark plug cap
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
1
To remove a spark plug
1. Remove cowling B. (See page
6-8 for cowling removal and
installation procedures.)
2. Remove the spark plug cover by
pulling it out as shown.1. Spark plug cover
1
4. Remove the spark plug as
shown with the spark plug
wrench included in the owner’s
tool kit.1. Spark plug wrench
5GJ-9-EV 5/26/01 11:04 AM Page 51
Page 53 of 100
6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9To check the spark plugs
1. Check that the porcelain insula-
tor around the center electrode
on each spark plug is a medium-
to-light tan (the ideal color when
the scooter is ridden normally).
2. Check that all spark plugs
installed in the engine have the
same color.
NOTE:
If any 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
scooter.3. Check each spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and
replace it if necessary.To install a spark plug
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, 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.
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.
Specified spark plug:
CR7E (NGK)
Spark plug gap:
0.7–0.8 mm
Tightening torque:
Spark plug:
12.5 Nm (1.25 m0kg)
a
a. Spark plug gap
5GJ-9-EV 5/26/01 11:04 AM Page 52
Page 54 of 100
6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU03872
Engine oil and oil filter
cartridgeThe engine oil level should be
checked before each ride. In addition,
the oil must be changed and the oil
filter cartridge replaced at the inter-
vals specified in the periodic mainte-
nance and lubrication chart.
To check the engine oil level
1. Place the scooter on the center-
stand.
ECA00081
cCThe engine must be cold before
proceeding with the oil level
check, otherwise the check will
result in a false reading. NOTE:
Make sure that the scooter is posi-
tioned straight up when checking the
oil level. A slight tilt to the side can
result in a false reading.
32
1
4
1. Engine oil level check window
2. Maximum level
3. Minimum level
4. Engine oil drain bolt2. Start the engine, warm it up for
two minutes, and then turn it off.
3. Wait two minutes until the oil set-
tles, and then check the oil level
through the check window locat-
ed at the bottom-left side of the
crankcase.NOTE:
The engine oil should be between the
minimum and maximum level marks.4. If the engine oil is below the min-
imum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
1
1. Spark plug cover5. Place the spark plug cover in the
original position as shown, and
then install the cowling.
5GJ-9-EV 5/26/01 11:04 AM Page 53
Page 55 of 100
6-13
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9To change the engine oil (with or
without oil filter cartridge 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 drain bolt to drain the oil
from the crankcase.
NOTE:
Skip steps 4–6 if the oil filter cartridge
is not being replaced.
4. Remove the oil filter cartridge
with an oil filter wrench.NOTE:
An oil filter wrench is available at a
Yamaha dealer.5. Apply a thin coat of engine oil to
the O-ring of the new oil filter
cartridge.NOTE:
Make sure that the O-ring is properly
seated.
1
1. Engine oil filler cap
2
1
1. Oil filter wrench
2. Oil filter cartridge
6. Install the new oil filter cartridge,
and then tighten it to the speci-
fied torque with a torque wrench.
7. Install the engine oil drain bolt,
and then tighten it to the speci-
fied torque.
1
1. Torque wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m0kg)Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m0kg)
5GJ-9-EV 5/26/01 11:04 AM Page 54
Page 56 of 100
6-14
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9 8. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil
filler cap.
Recommended oil:
SAE 10W-30 or 10W-40
(API SE, SF, SG or higher)
Oil quantity:
Without oil filter cartridge
replacement:
2.8 L
With oil filter cartridge
replacement:
2.9 L
Total amount (dry engine):
3.6 L
EC000072
cC8In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives
with the oil or use oils of a
higher grade than “CD”. In
addition, do not use oils
labeled “ENERGY CONSERV-
ING II” or higher.
8Make sure that no foreign
material enters the crankcase.9. Start the engine, and then let it
idle for several minutes while
checking it for oil leakage. If oil is
leaking, immediately turn the
engine off and check for the
cause.10. Turn the engine off, and then
check the oil level and correct it if
necessary.
5GJ-9-EV 5/26/01 11:04 AM Page 55
