2004 YAMAHA VERSITY 300 engine

PERIODIC MAINTENANCE AND MINOR REPAIR
6
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark1. Engine oil drain bolt
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3. Wait a few minutes until the oil
settles, remove the oil filler cap,
wipe the dipstick clean, insert it
back into the oil filler hole (without
screwing it in), and then remove
it again to check the oil level.
NOTE :
The engine oil should be between the
minimum and maximum level marks.4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
To change the engine oil
1. Start the engine, warm it up for
several minutes, and then turn it off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and the engine oil drain bolt to
drain the oil from the crankcase.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6CAUTION:
1. Engine oil drain bolt
2. Washer
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4. Check the washer for damage and
replace it if necessary.
5. Install the washer and the engine
oil drain bolt, and then tighten the
drain bolt to the specified torque.
Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m
•kgf)
NOTE :
Make sure that the washer is properly
seated.6. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
Recommended engine oil:
See page 8-1.
Oil quantity:
Periodic oil change:
1.2 L
Total amount (dry engine):
1.4 L7. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
8. Reset the oil change indicator.
(See page 3-7 for details.)
ECA00140
•Do not use oils with a diesel
specification of "CD" or oils of a
higher quality than specified. In
addition, do not use oils labeled
"ENERGY CONSERVING II" or
higher.
•Be sure no foreign material
enters the crankcase.

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04228
Final transmission oil
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 transmis-
sion 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 mi-
nutes, and then stop the engine.
2. Place the scooter on the
centerstand.
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.
Tightening torque:
Final transmission oil drain bolt:
22 Nm (2.2 m
•kgf)
6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten the
oil filler cap.
1. Final transmission oil filler cap1. Final transmission oil drain bolt
Recommended final transmission
oil:
See page 8-2.
Oil quantity:
0.25 L
EWA00062
•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.
WARNING
6-16
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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
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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
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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)
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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
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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
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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