2004 YAMAHA AEROX50 warning

PERIODIC MAINTENANCE AND MINOR REPAIR
6
1
ZAUM0276
1. Air filter element
5. Install the cowling.
NOTE :
If the engine overheats, see page 6-24
for further instructions.
1
ZAUM0275
1. Screws
EAUM0071
Cleaning the air filter
element
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more
frequently if you are riding in unusually
wet or dusty areas.
1. Remove the air filter case cover
by removing the screws.2. Pull the air filter element out, clean
it with solvent, and then squeeze
the remaining solvent out.
EW000075
Use only a dedicated parts cleaning
solvent. To avoid the risk of fire or
explosion, do not use gasoline or
solvents with a low flash point.
EC000089
To avoid damaging the foam material,
handle it gently and carefully, and do
not twist or wring it.
WARNING
CAUTION:
6-9

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04551
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.
EW000082
•The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
•The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger,
cargo, and accessories
approved for this model.
WARNING
0 12
3
4
ZAUM0053
Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg*150 kPa
1.5 kgf/cm
2
1.5 bar150 kPa
1.5 kgf/cm
2
1.5 bar
90 kg ~
maximum*
150 kPa
1.5 kgf/cm2
1.5 bar170 kPa
1.7 kgf/cm
2
1.7 bar
Maximum load* 180 kg
* Total weight of rider, passenger, cargo and
accessories
6-11
a
ZAUM0051
EAU00635
Adjusting the throttle cable
free play
The throttle cable free play should
measure 1.0 — 3.0 mm at the throttle
grip. Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
a Throttle cable free play

PERIODIC MAINTENANCE AND MINOR REPAIR
6 Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail
or glass fragments in it, or if the sidewall
is cracked, have a Yamaha dealer re-
place the tire immediately.
1
2
ZAUM0054
1. Tread depth
2. Side wall
Tire information
This scooter is equipped with tubeless
tires.
Minimum tire tread depth
(front and rear)1.6 mm
NOTE :
The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
Front
Manufacturer Size Type
PIRELLIM 130/60-13M SL36
Rear
Manufacturer Size Type
MICHELINM 130/60-13M BOPPER
PIRELLIM 130/60-13M EVO 21
PIRELLIM 140/60-13M SL36
MICHELINM 140/60-13M BOPPER
PIRELLIM 140/60-13 M EVO 22
6-12
EW000077
Because loading has an enormous
impact on the handling, braking, per-
formance and safety characteristics of
your scooter, you should keep the
following precautions in mind.
•NEVER OVERLOAD THE SCOO-
TER! 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.
•Do not carry along loosely
packed items, which can shift
during a ride.
•Securely pack the heaviest items
close to the center of the scooter
and distribute the weight evenly
on both sides.
•Adjust the suspension and tire air
pressure with regard to the load.
•Check the tire condition and air
pressure before each ride.
WARNING

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAUM0056
Adjusting the front and rear
brake lever free play
The front and rear brake lever free play
should measure 10 — 20 mm as shown.
Periodically check the front and rear
brake lever free play and, if necessary,
have a Yamaha dealer adjust it.
EW000100
An incorrect brake lever free play
indicates a hazardous condition in
the brake system. Do not operate the
scooter until the brake system has
been checked or repaired by a
Yamaha dealer.
WARNING
a
ZAUM0107
a
ZAUM0108
a Front brake lever free playa Rear brake lever free play
6-13
EAU03773
Cast wheels
To maximize the performance,
durability, and safe operation of your
scooter, note the following points
regarding the specified wheels.
•The wheel rims should be
checked for cracks, bends or
warpage before each ride. If any
damage is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair
to the wheel. A deformed or
cracked wheel must be replaced.
•The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse
handling characteristics, and a
shortened tire life.
•Ride at moderate speeds after
changing a tire since the tire surface
must first be "broken in" for it to
develop its optimal characteristics.

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
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