2004 YAMAHA JOG50R coolant

SAFETY INFORMATION.....................1-1
DESCRIPTION.....................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments .................2-3
INSTRUMENT AND CONTROL
FUNCTIONS........................................3-1
Main switch/steering lock .................3-1
Indicator lights ..................................3-1
Speedometer unit .............................3-2
Fuel gauge ........................................3-3
Clock .................................................3-3
Handlebar switches ..........................3-3
Front brake lever...............................3-4
Rear brake lever................................3-4
Fuel and 2 stroke engine oil
tank caps .......................................3-4
2-Stroke engine oil ...........................3-5
Kickstarter.........................................3-6
Seat...................................................3-6
Storage compartment.......................3-6
PRE-OPERATION CHECKS...............4-1
Pre-operation check list....................4-2
OPERATION AND IMPORTANT RIDING
POINTS................................................5-1
Starting a cold engine ......................5-1
Starting off ........................................5-1Acceleration and deceleration ..........5-2
Braking..............................................5-2
Engine break-in.................................5-2
Parking ..............................................5-2
PERIODIC MAINTENANCE AND
MINOR REPAIRS................................6-1
Periodic maintenance and
lubrication chart ............................6-2
Checking the spark plug ..................6-5
Final transmission oil ........................6-6
Coolant (only for liquid-cooled
models) ..........................................6-6
To check the coolant level ................6-7
Cleaning the air filter element ...........6-8
Adjusting the carburetor ...................6-9
Adjusting the throttle cable
free play .........................................6-9
Tires ..................................................6-9
Adjusting the front brake lever
free play .......................................6-11
Adjusting the rear brake lever
free play .......................................6-11
Cheking the front brake pads
and rear brake shoes ..................6-12
Checking the front brake fluid
level .............................................6-13
Changing the brake fluid ................6-13
Checking and lubricating the
cables ..........................................6-13Checking and lubricating the
throttle grip and cable .................6-14
Adjusting the autolube pump .........6-14
Lubricating the front and rear
brake levers .................................6-14
Checking and lubricating the
centerstand .................................6-14
Checking the front fork ...................6-15
Checking the steering.....................6-15
Checking the wheel bearings .........6-15
Replacing the headlight bulb or
a front turn signal light bulb ........6-16
Replacing a turn signal light bulb
or the tail/brake light bulb ...........6-16
Replacing the license plate light
bulb .............................................6-17
Battery ............................................6-17
Replacing the fuse ..........................6-18
Troubleshooting ..............................6-19
Troubleshooting chart .....................6-20
SCOOTER CARE AND STORAGE.....7-1
Care ..................................................7-1
Storage compartment.......................7-3
SPECIFICATIONS...............................8-1
CONSUMER INFORMATION.............9-1
TABLE OF CONTENTS
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EAU10420
Right view
DESCRIPTION
2-2
2
9. Wheel (Front) (page 6-15)
10. Right rear blinker (page 6-16)
11. Tail light (page 6-16)
12. Fuel tank (page 3-4)13. Storage compartment (page 3-6)
14. Battery (page 6-17)
15. Wheel (Rear) (page 6-15)
16. Coolant reservoir (page 6-7)
15
10 1112 13 14
16
9
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EAU10430
Controls and instruments
DESCRIPTION
2-3
2
17. Rear brake lever (page 6-11)
18. Left handlebar switch (page 3-3)
19. Speedometer (page 3-2)
20. Turn signal indicator light (page 3-1)
21. High beam light (page 3-1)
22. Oil level warning light (page 3-1)
23. Coolant temperature warning light (page 3-1)
24. "TRIP" button (page 3-2)25. Fuel gauge (page 3-3)
26. Front brake lever (page 3-4 )
27. Right handlebar switch (page 3-3)
28. Turn signal switch (page 3-3)
29. Horn switch (page 3-3)
30. Main switch (page 3-1)
31. Coolant level gauge window (page 6-7)
kb
ajd
z
c4050
30
10 2060
70
80
0
y
17
2928
31 30 2726
20 21
25 23 19 20
18
2422
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EAU10460
Main switch/steering lock
The main switch/steering lock con-
trols the ignition and lighting systems,
and is used to lock the steering. The
various positions are described
below.
EAU10630
ON
All electrical systems are supplied
with power, and the engine can be
started. The key cannot be removed.
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 3-1.)
EAU10680
LOCK
The steering is locked, and all electri-
cal systems are off. The key can be
removed.
T
o lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF”
position, and then turn it to
“LOCK” while still pushing it.
3. Remove the key.
T
o unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
EWA10060
s s
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 vehi-
cle is stopped before turning the
key to “OFF” or “LOCK”.
EAU10980
Indicator lights
1. Turn signal indicator lights “b”
2. High beam indicator light “j”
3. Oil level warning light “z”
4. Coolant temperature warning light “y”
j
d
z
c4050
30
10 2060
70
80
0
y
00000.0
23:08TOTALExF
3
INSTRUMENT AND CONTROL FUNCTIONS
3-1
2 1
4
3
1
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EAU11030
Turn signal indicator lights “c” and
“d”
The corresponding indicator light flas-
hes when the turn signal switch is
pushed to the left or right.
EAU11080
High beam indicator light “j”
This indicator light comes on when
the high beam of the headlight is swit-
ched on.
EAU11130
2-stroke engine oil level warning
light “z”
This warning light comes on when the
2-stroke engine oil level is low.
The electrical circuit of the warning
light can be checked according to the
following procedure.
1. Turn the key to “ON”.
2. Shift the transmission into the
neutral position.
3. If the warning light does not
come on, have a Yamaha dealer
check the electrical circuit.
ECA11570
CAUTION
Do not operate the motorcycle until
you know that the 2-stroke engine
oil level is sufficient.
NOTE:
Even if the 2-stroke engine oil level is
sufficient, the warning light may flic-
ker when riding on a slope or during
sudden acceleration or deceleration,
but this is not a malfunction.
EAU11430
Coolant temperature warning light
“y”
This warning light comes on when the
engine overheats. When this occurs,
stop the engine immediately and
allow the engine to cool.
ECA10020
CAUTION
Do not operate the engine if it is
overheated.
EAUM1090
Speedometer unit
1. Speedometer unit
2. Fuel gauge
3. Clock
4. Odometer (TOTAL/TRIP)
5. “TRIP” button
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 trip-
meter shows the distance traveled
since it was last set to zero.
Pushing the reset button switches the
display between the odometer mode
“TOTAL” and the tripmeter mode
“TRIP”. To reset the tripmeter, enter
the “TRIP” mode, and then hold down
j
d
z
c4050
30
10 2060
70
80
0
y
00000.0
23:08TOTALExF
3
INSTRUMENT AND CONTROL FUNCTIONS
3-2
14
3
2 5
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ITEM CHECKS PAGE
Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.—
Instruments, lights, • Check operation.
signals and switches• Correct if necessary.—
• Check coolant level in reservoir.
Coolant• If necessary, add recommended coolant to specified level. 6-6, 6-7
• Check cooling system for leakage.
PRE-OPERATION CHECKS
4-3
4
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ODOMETER READING (x 1000 Km) ANNUAL
NOITEM CHEK OR MAINTENANCE JOB 1 6 12 18 24CHECK
9*Wheel bearings• Check bearing for looseness or damage.√√√√
10 *Steering bearings• Check bearing play and steering for roughness.√√ √ √√• Lubricate with lithium-soap-based grease. Every 24000 km
11 *Chassis fasteners• Make sure that all nuts, bolts and screws are
properly tightened.√√√√ √
12Centerstand• Check operation.
• Lubricate.√√√√ √
13 *Front fork• Check operation and for oil leakage.√√√√
14 *Shock absorber
• Check operation and shock absorber for oil leakage.√√√√
assembly
15 *Carburetor• Adjust engine idling speed.√√ √ √√ √
16 *Autolube pump• Check operation.
• Bleed if necessary.√√√√
17 *Cooling system• Check coolant level and vehicle for coolant leakage.√√√√ √• Change. Every 3 years
18Final transmission • Check vehicle for oil leakage.√√ √oil
• Change.√√√
19 *V-belt• Replace. Every 12000 km
20 *Front and rear brake
• Check operation.√√ √ √√ √
switches
21Moving parts and
• Lubricate.√√√√ √
cables
22 *Lights, signals • Check operation.
and switches• Adjust headlight beam.√√ √ √√ √
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
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EAU20060
Final transmission oil
1. Oil filler bolt
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 trans-
mission 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 engi-
ne.
1. Drain plug
2. Place the scooter on the centers-
tand.
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.
5. Install the final transmission oil
drain bolt, and then tighten it to
the specified torque.
6. Add the specified amount of the
recommended final transmissionoil, and then install and tighten
the oil filler cap.
EWA11310
s s
WARNING
Make sure that no foreign
material enters the final trans-
mission 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.
EAUS1200
Coolant (only for liquid-
cooled models)
The coolant level should be checked
before each ride. In addition, the coo-
lant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended final transmission
oil:
SAE30 motor oil.
Oil quantity:
0,11 L (0,0003 Imp.qt)
Tightening torque:
Final transmission oil drain bolt:
18 Nm (1,8 m•kgf, 13,2 ft•lbf)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
11
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