2004 YAMAHA VERSITY 300 maintenance

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01139
Removing and installing
cowlings and panels
The cowlings and panels shown above
need to be removed to perform some
of the maintenance jobs described in
this chapter. Refer to this section each
time a cowling or panel needs to be
removed and installed.
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1. Cowling A 1. Cowling B
6-5
1
2
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1. Windshield
2. Panel A

PERIODIC MAINTENANCE AND MINOR REPAIR
6
1
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1
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1. Panel B 1. Panel C
6-6
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1. Panel D

PERIODIC MAINTENANCE AND MINOR REPAIR
6
1. Cowling A
2. Screw (x 8)
3. Floorboard mat (x2)1. Turn signal lead coupler
2. Headlight coupler
6-7
3 2 1
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Cowling A
To remove the cowling
1. Pull up the floorboard mat on each
side of the scooter.
2. Remove panel A. (See page 6-9
for removal and installation
procedures.)
3. Remove the cowling screws.4. Disconnect the headlight coupler
and the turn signal lead coupler.
5. Pull the cowling off.
To install the cowling
1. Connect the headlight coupler,
and the turn signal lead coupler.
2. Place the cowling in the original
position, and then install the
screws.
3. Install panel A.
4. Place the floorboard mats in their
original position.
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1. Panel E

PERIODIC MAINTENANCE AND MINOR REPAIR
6
1. Floorboard mat (x2)
1. Screw (x 4)
2. Cowling B 1. Screw (x5)
2. Cowling B
6-8
1
2
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Cowling B
To remove the cowling
1. Pull up the floorboard mat on each
side of the scooter.2. Remove the screws on each side
of scooter, and then take the
cowling off.To install the cowling
1. Place the cowling in the original
position, and then install the
screws.
2. Place the floorboard mats in their
original position.

PERIODIC MAINTENANCE AND MINOR REPAIR
6
1. Windshield
2. Screw (x4)1. Screw (x2)
2. Panel A
6-9
2 1
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1
2
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Panel A
To remove the panel
1. Remove the screws, and then take
the windshield off.2. Remove the screws, and then pull
the panel out as shown.
To install the panel
1. Place the panel in the original po-
sition, and then install the screws.
2. Place the windshield in the origi-
nal position, and then install the
screws.
EAU01535
Panel B
To remove the panel
Remove the screw, and then pull the
panel off as shown.
To install the panel
Place the panel in the original position,
and then install the screw.
1. Screw (x1)
2. Panel B
1
2
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
1. Floorboard mat
6-10 1. Panel C
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Panel C
To remove the panel
1. Pull up the right floorboard mat.2. Remove the panel as shown.To install the panel
1. Place the panel in the original
position.
2. Place the floorboard mat in the
original position.
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Panel D
To remove the panel
Pull the panel off as shown.
To install the panel
Place the panel in the original position.
1. Panel D
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03620
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic main-
tenance and lubrication chart. In addi-
tion, the condition of the spark plug can
reveal the condition of the engine.
To remove the spark plug
1. Remove cowling B. (See page 6-
8 for cowling removal and instal-
lation procedures.)
2. Remove the spark plug cap.
1. Spark plug
6-11
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EAU01535
Panel E
To remove the panel
Remove the screw, and then pull the
panel off as shown.
To install the panel
Place the panel in the original position,
and then install the screw.
1. Panel E
2. Screw

PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. Remove the spark plug as shown,
with the spark plug wrench
included in the owner's tool kit.To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light
tan (the ideal color when the scoo-
ter is ridden normally).
NOTE :
If the spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the scooter.
2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
Specified spark plug:
DR8EA (NGK)To install the spark plug
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
Spark plug gap:
0.6 – 0.7 mm
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
1. Spark plug wrencha. Spark plug gap
6-12
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a
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