2004 YAMAHA VERSITY 300 brake

PRE-OPERATION CHECKS
4The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or
loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual
inspection, to check the following points before each ride.
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Pre-operation check list
ITEM CHECKS PAGE
•Check fuel level in fuel tank.
Fuel•Refuel if necessary. 3-3 — 3-4, 3-10 — 3-11
•Check fuel line for leakage.
•Check oil level in engine.
Engine oil•If necessary, add recommended oil to specified level. 6-13 — 6-15
•Check vehicle for oil leakage.
Final transmission oil•Check vehicle for oil leakage. 6-16
•Check coolant level in reservoir.
Coolant•If necessary, add recommended coolant to specified level. 6-17
•Check cooling system for leakage.
•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
Front brake•Check fluid level in reservoir. 3-9, 6-23 — 6-25
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.
•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
Rear brake•Check fluid level in reservoir. 3-9, 6-23 — 6-25
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.
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4
PRE-OPERATION CHECKS
ITEM CHECKS PAGE
•Make sure that operation is smooth.
Throttle grip•Check cable free play.
6-20, 6-26
•If necessary, have Yamaha dealer adjust cable free play
and lubricate cable and grip housing.
•Check for damage.
Wheels and tires•Check tire condition and tread depth.
6-21 — 6-23
•Check air pressure.
•Correct if necessary.
Brake levers•Make sure that operation is smooth.
3-9, 6-23, 6-26
•Lubricate lever pivoting points if necessary.
Centerstand, sidestand•Make sure that operation is smooth.
6-27
•Lubricate pivots if necessary.
Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.
—
•Tighten if necessary.
Instruments, lights•Check operation.
3-1 — 3-8, 6-32 — 6-35
signals and switches•Correct if necessary.
Sidestand switch•Check operation of ignition circuit cut-off system.
3-16
•If system is defective, have Yamaha dealer check vehicule.
4-2

OPERATION AND IMPORTANT RIDING POINTS
5
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EW000129
•Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or
function that you do not
thoroughly understand.
•Never start the engine or
operate it in a closed area for
any length of time. Exhaust fu-
mes are poisonous, and
inhaling them can cause loss of
consciousness and death
within a short time. Always
make sure that there is
adequate ventilation.
•For safety, always start the
engine with the centerstand
down.
WARNING
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Starting the engine
See page 5-4 for engine break-in ins-
tructions prior to operating the
vehicle for the first time.
In order for the ignition circuit cut-off
system to enable starting, the sidestand
must be up.
EW000054
•Before starting the engine,
check the function of the igni-
tion circuit cut-off system
according to the procedure
described on page 3-16.
•Never ride with the sidestand
down.1. Turn the key to "
" and make
sure that the engine stop switch
is set to "
".
2. Close the throttle completely.
3. Start the engine by pushing the
start switch while applying the
front or rear brake.
CAUTION:
WARNING
1234
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1. Rear brake lever
2. Engine stop switch
3. Start switch
4. Front brake lever
5-1

OPERATION AND IMPORTANT RIDING POINTS
5
NOTE :
If the engine does not start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to
preserve the battery. Do not crank the
engine more than 10 seconds on any
one attempt. If the engine does not
start, try with the throttle open 1/8 turn.
ECA00045
For maximum engine life, never
accelerate hard when the engine is
cold!
CAUTION:
1
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1. Grab bar
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Starting off
NOTE :
Before starting off, allow the engine to
warm up.
1. While pulling the rear brake lever
with your left hand and holding the
grab bar with your right hand,
push the scooter off the
centerstand.
2. Sit astride the seat, and then
adjust the rear view mirrors.3. Switch the turn signal on.
4. Check for oncoming traffic, and
then slowly turn the throttle grip
(on the right) in order to take off.
5. Switch the turn signal off.
5-2

OPERATION AND IMPORTANT RIDING POINTS
5
a b
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Acceleration and
deceleration
The speed can be adjusted by opening
and closing the throttle. To increase the
speed, turn the throttle grip in direction
a . To reduce the speed, turn the
throttle grip in direction b .
PUSHZAUM0472
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Braking
1. Close the throttle completely.
2. Apply both front and rear brakes
simultaneously while gradually
increasing the pressure.
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•Avoid braking hard or suddenly
(especially when leaning over
to one side), otherwise the
scooter may skid or overturn.
•Railroad crossings, streetcar
rails, iron plates on road cons-
truction sites, and manhole
covers become extremely
slippery when wet. Therefore,
slow down when approaching
such areas and cross them with
caution.
•Keep in mind that braking on a
wet road is much more difficult.
•Ride slowly down a hill, as
braking downhill can be very
difficult.
WARNING
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PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit ........................................................ 6-1
Periodic maintenance and lubrication chart ............ 6-2
Removing and installing cowlings and panels ........ 6-5
Checking the spark plug ....................................... 6-11
Engine oil .............................................................. 6-13
Final transmission oil ............................................ 6-16
Coolant .................................................................. 6-17
Air filter and the V-belt case air filter elements ...... 6-18
Adjusting the carburetor ........................................ 6-20
Adjusting the throttle cable free play ..................... 6-20
Adjusting the valve clearance ............................... 6-21
Tires ...................................................................... 6-21
Cast wheels .......................................................... 6-23
Adjusting the front and rear brake lever
free play ................................................................ 6-23
Checking the front and rear brake pads ................ 6-24
Checking the brake fluid level ............................... 6-24
Changing the brake fluid ....................................... 6-25Checking and lubricating the cables ..................... 6-26
Checking and lubricating the throttle grip
and cables ............................................................. 6-26
Lubricating the front and rear brake levers ........... 6-26
Checking and lubricating the centerstand
and sidestand ........................................................ 6-27
Checking the front fork .......................................... 6-27
Checking the steering ........................................... 6-28
Checking the wheel bearings ................................ 6-29
Battery ................................................................... 6-29
Replacing the fuses .............................................. 6-30
Replacing a headlight bulb .................................... 6-32
Replacing a front turn signal light bulb .................. 6-34
Replacing tail/brake light bulb
or rear turn signal light bulb .................................. 6-34
Replacing the license plate light bulb .................... 6-35
Troubleshooting ..................................................... 6-35
Troubleshooting charts .......................................... 6-36
6

PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Periodic maintenance and lubrication chart
NOTE :
•The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
•From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
•Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
1 * Fuel line•Check fuel hoses and vacuum hose for cracks or damage.√√√√ √
•Check condition.
√√
2 Spark plug•Clean and regap.
•Replace.√√
3 * Valves•Check valve clearance.
√√
•Adjust.
4 Air filter element•Clean.√√•Replace.√√
5 V-belt case air filter element•Clean.√√√√
•Check operation, fluid level and vehicle for fluid leakage.
√√√√√ √
6 * Front brake(See NOTE on page 6-4.)
•Replace brake pads. Whenever worn to the limit
ODOMETER READING (x 1,000 km)
NO. ITEMCHECK OR MAINTENANCE JOB
1
ANNUAL
CHECK
10 20 30 40
6-2

PERIODIC MAINTENANCE AND MINOR REPAIR
6
•Check operation, fluid level and vehicle for fluid leakage.
√√√√√ √7 * Rear brake(See NOTE on page 6-4.)
•Replace brake pads. Whenever worn to the limit
8 * Brake hoses•Check for cracks or damage.√√√√ √•Replace. (See NOTE on page 6-4.) Every 4 years
9 * Wheels•Check runout and for damage.√√√√
•Check tread depth and for damage.
10 * Tires•Replace if necessary.
√√√√ √
•Check air pressure.
•Correct if necessary.
11 * Wheel bearings•Check bearing for looseness or damage.√√√√
12 * Steering bearings•Check bearing play and steering for roughness.√√√√√•Lubricate with lithium-soap-based grease. Every 20,000 km
13 * Chassis fasteners•Make sure that all nuts, bolts and screws are
√√√√ √
properly tightened.
14 Sidestand, Centerstand•Check operation.
√√√√ √
•Lubricate.
15 * Sidestand switch•Check operation.√√√√√ √
16 * Front fork•Check operation and for oil leakage.√√√√
17 * Shock absorber assemblies•Check operation and shock absorbers for oil leakage.√√√√
18 * Carburetor•Adjust engine idling speed.√√√√√ √
ODOMETER READING (x 1,000 km)
NO. ITEMCHECK OR MAINTENANCE JOB
1
ANNUAL
CHECK
10 20 30 40
6-3