2004 YAMAHA VERSITY 300 check engine

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04591*
Coolant
The coolant reservoir is located under
the panel B. (See page 6-9 for panel
removal and installation procedures.)
To check the coolant level
1. Place the scooter on a level sur-
face and hold it in an upright posi-
tion.
NOTE :
•The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
•Make sure that the scooter is
positioned straight up when
checking the coolant level. A slight
tilt to the side can result in a false
reading.2. Check the coolant level in the
coolant reservoir.
NOTE :
The coolant should be between the
minimum and maximum level marks.
1. Maximum level mark
2. Minimum level mark
3. If the coolant is at or below the
minimum level mark, remove the
reservoir cap, add coolant to the
maximum level mark, and then
install the reservoir cap.
Coolant reservoir capacity:
0.4 L
4. Install the panel.
1. Coolant reservoir cap
6-17
1
2
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EC000080
•If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water or
salt water since it is harmful to
the engine.
•If water has been used instead of
coolant, replace it with coolant as
soon as possible, otherwise the
engine may not be sufficiently
cooled and the cooling system
will not be protected against frost
and corrosion.
•If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of the
coolant will be reduced.
NOTE :
The radiator fan is automatically
switched on or off according to the
coolant temperature in the radiator. If
the engine overheats, see page 6-37
for further instructions.
CAUTION:EAU03627*
Air filter and V-belt case air
filter elements
The air filter and V-belt case air filter
elements should be cleaned at the
intervals specified in the periodic main-
tenance and lubrication chart. Clean
both filter elements more frequently if
you are riding in unusually wet or dusty
areas.
EC000092*
•Make sure that each filter
element is properly seated in its
case.
•The engine should never be
operated without the filter
elements installed, otherwise
the piston and/or cylinder may
become excessively worn.Cleaning the air filter element
1. Place the scooter on the
centerstand.
2. Remove the air filter case cover
by removing the screws.
CAUTION:
1. Air filter case cover
2. Screw (x5)
3. Sponge material
4. Mesh sheet
6-18
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2 2
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PERIODIC MAINTENANCE AND MINOR REPAIR
63. Pull the sponge material out along
with the mesh sheet, clean it with
solvent, and then squeeze the
remaining solvent out.
4. Check the sponge material for
damage and replace it if
necessary.
5. Allow the sponge material to dry.
6. Apply oil of the recommended
type to the entire surface of the
sponge material, and then
squeeze the excess oil out.
NOTE :
The sponge material should be wet but
not dripping.
Recommended oil:
Engine oil
7. Insert the sponge material into the
air filter case.
8. Install the air filter case cover by
installing the screws.
Cleaning the V-belt case air filter
element
1. Remove the V-belt case air filter
cover by removing the screws.
1. V-belt case air filter cover
2. Screw (x3)
6-19
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PERIODIC MAINTENANCE AND MINOR REPAIR
6 2. Blow the dirt out of the air filter
element with compressed air as
shown.
3. Check the V-belt case air filter
element for damage and replace
it if necessary.
4. Install the V-belt case air filter
element cover by installing the
screws.
1. V-belt case air filter cover
2. V-belt case air filter element
EAU00631
Adjusting the carburetor
The carburetor is an important part of
the engine and requires very
sophisticated adjustment. Therefore, all
carburetor adjustments should be left
to a Yamaha dealer, who has the
necessary professional knowledge and
experience.
EAU00635
Adjusting the throttle cable
free play
The throttle cable free play should
measure 1.5 – 3 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
6-20
21
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a
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00637
Adjusting the valve clea-
rance
The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
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
Maximum load* 202 k g
* Total weight of rider, passenger, cargo and
accessories
6-21
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3
4
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Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg*180 kPa
1.8 kgf/cm
2
1.8 bar190 kPa
1.9 kgf/cm
2
1.9 bar
90 kg ~ 160 kg load*
180 kPa
1.8 kgf/cm2
1.8 bar200 kPa
2.0 kgf/cm
2
2.0 bar
160 kg ~
maximum load*
190 kPa
1.9 kgf/cm2
1.9 bar220 kPa
2.2 kgf/cm
2
2.2 bar

PERIODIC MAINTENANCE AND MINOR REPAIR
6
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
EAU04034
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in the
periodic maintenance chart.
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)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6 To 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
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.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01581
Troubleshooting charts
Starting problems or poor engine performanceEW000125
Keep away open flames and do not smoke while checking or working on the fuel system.
WARNING
Check the fuel level in
the fuel tank.
1. FuelThere is enough fuel.
There is no fuel.Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.
2. CompressionThere is compression.
There is no compression.Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.
3. IgnitionWipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.
4. BatteryThe engine turns over
quickly.
The engine turns over
slowly.The battery is good.
Check the battery lead connections,
and charge the battery if necessary.
Dry
WetOpen the throttle halfway and operate
the electric starter.
6-36