2003 YAMAHA AEROX50 steering

2
DESCRIPTION
Left view
1. Rear brake lever (page 3-5, 6-13, 6-16)
2. Left handlebar switches (page 3-4)
3. Speedometer (page 3-3)
4. Main switch/steering lock (page 3-1, 3-9)
2-1
1
23
4
68
7
5
5. Final transmission oil filler cap (page 6-7)
6. Centerstand (page 6-16)
7. Kick starter (page 3-7)
8. Air filter (page 6-9)

EAU00027
INSTRUMENT AND CONTROL FUNCTIONS
Main switch / steering lock .................................................................. 3-1
Indicator and warning lights ................................................................ 3-2
Coolant temperature warning light ...................................................... 3-2
Speedometer unit ................................................................................ 3-3
Tachometer (depends on model) ........................................................ 3-3
Fuel gauge .......................................................................................... 3-3
Handlebar switches ............................................................................. 3-4
Front brake lever ................................................................................. 3-5
Rear brake lever .................................................................................. 3-5
Fuel tank cap ...................................................................................... 3-5
Fuel .....................................................................................................\o 3-6
Catalytic converter .............................................................................. 3-7
Kick starter .......................................................................................... 3-7
2-stroke engine oil tank cap ................................................................ 3-8
2-stroke engine oil ............................................................................... 3-8
Starter (choke) lever ............................................................................ 3-9
Rider seat ............................................................................................ 3-9
Storage compartment A .................................................................... 3-10
Storage compartment B .................................................................... 3-11
Adjusting the shock absorber assembly (depends on model) ........... 3-11
3

3
INSTRUMENT AND CONTROL FUNCTIONS
EAU00029
Main switch/steering 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.
PUSH
OPEN
ZAUM0253
EAU00038
OFF “ ”
All electrical systems are off. The key
can be removed.
EAU04470
CHECK “”
The 2-stroke engine oil level warning
light should come on. See page 3-2 for
an explanation of the engine oil level
warning light.
EAU00040
LOCK “ ”
The steering is locked, and all electrical
systems are off. The key can be
removed.
To lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “
”
position, and then turn it to “
”
while still pushing it.
3. Remove the key.
To unlock the steering
Push the key in, and then turn it to “
”
while still pushing it.
EW000016
Never turn the key to “ ” or “ ”
while the scooter is moving, otherwise
the electrical systems will be switched
off, which may result in loss of control
or an accident. Make sure that the scoo-
ter is stopped before turning the key
to “ ” or “ ”.
WARNING
3-1
EAU00037
ON “ ”
All electrical circuits are supplied with
power, and the engine can be started.
The key cannot be removed.
NOTE :
The headlight, meter lighting and
taillight come on automatically when the
engine is started.

EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR
Periodic maintenance and lubrication chart ............ 6-2
Removing and installing cowling and panel ............ 6-5
Cowling A ................................................................ 6-5
Panel A .................................................................... 6-5
Checking the spark plug ......................................... 6-6
Final transmission oil .............................................. 6-7
Coolant .................................................................... 6-8
Cleaning the air filter element ................................. 6-9
Adjusting the carburetor ........................................ 6-10
Adjusting the throttle cable free play ..................... 6-11
Tires ...................................................................... 6-11
Wheels .................................................................. 6-13
Adjusting the front and rear brake lever
free play ................................................................ 6-13
Checking the front and rear brake pads ................ 6-14
Checking the brake fluid level ............................... 6-14
6 Changing the brake fluid ....................................... 6-15
Adjusting the autolube pump ................................ 6-15
Checking and lubricating the cables ..................... 6-16
Lubricating the front and rear brakes levers .......... 6-16
Checking and lubricating the centerstand ............. 6-16
Checking the front fork .......................................... 6-17
Checking the steering ........................................... 6-17
Checking the wheel bearings ................................ 6-18
Battery ................................................................... 6-18
Replacing the fuse ................................................ 6-20
Replacing a headlight bulb .................................... 6-20
Replacing tail/brake light bulb ............................... 6-21
Replacing a turn signal light bulb .......................... 6-22
Troubleshooting ..................................................... 6-22
Troubleshooting chart ............................................ 6-23
Engine overheating ............................................... 6-24

PERIODIC MAINTENANCE AND MINOR REPAIR
6
• Check tread depth and for damage.
9 * Tires• Replace if necessary.
√√√√ √
• Check air pressure.
• Correct if necessary.
10 * Wheel bearings• Check bearing for looseness or damage.√√√√
11 * Steering bearings• Check bearing play and steering for roughness.√√√√√• Lubricate with lithium-soap-based grease. Every 24,000 km
12 * Chassis fasteners• Make sure that all nuts, bolts and screws are
√√√√ √
properly tightened.
13 Centerstand• Check operation.
√√√√ √
• Lubricate.
14 * Front fork• Check operation and for oil leakage.√√√√
15 * Shock absorber assembly• Check operation and shock absorber for oil leakage.√√√√
16 * Carburetor• Check starter (chocke) operation.
√√√√√ √
• Adjust engine idling speed.
17 * Autolube pump• Check operation.
√√√√
• Bleed if necessary.
18 Final transmission oil• Check vehicle for oil leakage.√√ √• Change.√√√
19 * V-belt• Replace. Every 10,000 km
20 * Front and rear brake
• Check operation.√√√√√ √
switches
ODOMETER READING (x 1,000 km)
NO. ITEMCHECK OR MAINTENANCE JOB
1
ANNUAL
CHECK
6121824
6-3

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.