2003 YAMAHA AEROX50 Owners Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6Observe these precautions:
•When checking the fluid level,
make sure that the top of the
master cylinder is level by turning
the handlebars.
•Use only the recommended
quality brake fluid, otherwise the
rubber seals may deteriorate,
causing leakage and poor braking
performance.
Recommended brake fluid:
DOT 4
NOTE :
If DOT 4 is not available, DOT 3 can be
used.
•Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
•Be careful that water does not
enter the master cylinder when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
•Brake fluid may deteriorate
painted surfaces or plastic parts.
Always clean up spilled fluid
immediately.
•As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
EAUM0008*
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and
lubrication chart. In addition, have the
brake hoses replaced every four years
or whenever there are damaged or
leaking.
6-15
EAU00774
Adjusting the Autolube pump
The Autolube pump is a vital and
sophisticated component of the engine,
which must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.

PERIODIC MAINTENANCE AND MINOR REPAIR
6
ZAUM0061
EAU03118
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 main-
tenance and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
ZAUM0062
EAU04123
Checking and lubricating the
centerstand
The operation of the centerstand should
be checked before each ride, and the
pivots and metal-to-metal contact sur-
faces should be lubricated if necessary.
EWA00055
If the centerstand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
WARNING
6-16
EAU02962
Checking and lubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the cables
and cable ends should be lubricated if
necessary. If a cable is damaged or does
not move smoothly, have a Yamaha dea-
ler check or replace it.
Recommended lubricant:
Engine oil
EW000112
Damage to the outer sheath may
interfere with proper cable operation
and will cause the inner cable to rust.
Replace a damaged cable as soon
as possible to prevent unsafe con-
ditions.
WARNING

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU02939
Checking the front fork
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.
To check the condition
EW000115
Securely support the scooter so that
there is no danger of it falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
WARNINGTo check the operation
1. Place the scooter on a level sur-
face and hold it in an upright po-
sition.
2. While applying the front brake,
push down hard on the
handlebars several times to check
if the front fork compresses and
rebounds smoothly.
EC000098
If any damage is found or the front
fork does not operate smoothly, have
a Yamaha dealer check or repair it.
CAUTION:
EAU00794
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Place a stand under the engine
to raise the front wheel off the
ground.
EW000115
Securely support the scooter so that
there is no danger of it falling over.
WARNING
6-17
ZAUM0296ZAUM0297

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01144
Checking the wheel bearings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and
lubrication 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.
1
ZAUM0281
1. Battery
EAUM0049
Battery
A poorly maintained battery will corrode
and discharge quickly. The electrolyte
level, battery lead connections and
breather hose routing should be
checked before each ride and at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the electrolyte level
1. Place the scooter on a level sur-
face and hold it in an upright posi-
tion.
NOTE :
Make sure that the scooter is positioned
straight up when checking the
electrolyte level.
2. Remove panel A. (See page 6-5
for panel removal and installation
procedures.)
3. Check the electrolyte level in the
battery.
NOTE :
The electrolyte should be between the
minimum and maximum level marks.
1
2+UPPER
LOWER
ZAUM0106
1. Maximum level
2. Minimum level
6-18
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the
steering.

PERIODIC MAINTENANCE AND MINOR REPAIR
64. If the electrolyte is at or below the
minimum level mark, add distilled
water to raise it to the maximum
level mark.
EW000116
•Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes
severe burns. Avoid any con-
tact 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
hydrogen 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 BATTE-
RIES OUT OF THE REACH OF
CHILDREN.
EC000100
Use only distilled water, as tap water
contains minerals that are harmful
to the battery.
5. Check and, if necessary, tighten
the battery lead connections and
correct the breather hose routing.
WARNING
CAUTION:
To store the battery
1. If the scooter 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 the
specific gravity of the electrolyte
at least once a month and fully
charge the battery whenever
necessary.
3. Fully charge the battery before
installation.
4. After installation, make sure that
the battery leads are properly
connected to the battery terminals
and that the breather hose is
properly routed, in good condition,
and not obstructed.
EC000099
If the breather hose is positioned in
such a way that the frame is exposed
to electrolyte or gas expelled from
the battery, the frame could suffer
structural and external damages.
CAUTION:
6-19

PERIODIC MAINTENANCE AND MINOR REPAIR
6
1
ZAUM0282
1. Fuse
EAU01307
Replacing the fuse
The fuse holder is located behind pa-
nel A. (See page 6-5 for panel removal
and installation procedures.)
If the fuse is blown, replace it as follows.
1. Turn the key to "
" and turn off
all electrical circuits.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
Specified fuse: 7.5 A
EC000103
Do not use a fuse of a higher
amperage rating than recommended
to avoid causing extensive damage
to the electrical system and possibly
a fire.
3. Turn the key to "
" 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.
CAUTION:
EAUM0072*
Replacing a headlight bulb
1. Remove cowling A
(See page 6-5 for cowling removal
and installation procedures.)
2. Remove the headlight coupler.
3. Remove the headlight bulb holder by
turning it 1/4 turn counterclockwise.
4. Remove the defective bulb.
EW000119
Headlight bulbs get very hot.
Therefore, keep flammable products
away from a lit headlight bulb, and
do not touch the bulb until it has
cooled down.
1
ZAUM0283
1. Headlight bulb
WARNING
6-20

PERIODIC MAINTENANCE AND MINOR REPAIR
65. Place a new headlight bulb into
position, and then secure it with
the bulb holder.
6. Connect the headlight coupler
and install the cowling A.
EC000105
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely
affected. Thoroughly clean off any
dirt and fingerprints on the headlight
bulb using a cloth moistened with
alcohol or thinner.
CAUTION:
ZAUM0284
6-21
EAUM0037
Replacing the brake/taillight
bulb
1. Remove the brake/taillight lens by
removing the screws.
2. Remove the brake/taillight bulb
holder by turning it 1/4 turn
counter-clockwise.
3. Remove the defective bulb.
4. Place a new bulb into position, and
then secure it with the bulb holder.
5. Place the brake/taillight lens in the
original position, and then install
the screw.

PERIODIC MAINTENANCE AND MINOR REPAIR
6
ZAUM0285ZAUM0286
EAU03218
Replacing a turn signal light
bulb
1. Remove the turn signal lens by
removing the screws.
2. Remove the defective bulb by
pushing it in and turning it
counterclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it
clockwise until it stops.
4. Install the lens by installing the
screws.
EC000108
Do not overtighten the screws,
otherwise the lens may break.
CAUTION:
EAU03087
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 charts
represent quick and easy procedures
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.
6-22