2004 YAMAHA WHY 50 brake fluid

PRE-OPERATION CHECKS
4
•Check fuel level in fuel tank.
Fuel•Refuel if necessary. 3-5 — 3-6
•Check fuel line for leakage.
•Check oil level in oil tank.
2-stroke engine oil•If necessary, add recommended oil to specified level. 3-5 — 3-7
•Check vehicle for oil leakage.
Final transmission oil•Check vehicle for oil leakage. 6-6
•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
Front brake•Check fluid level in reservoir. 3-5, 6-13 — 6-15
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.
•Check operation.
Rear brake•Check pedal free play. 3-5, 6-13 — 6-15
•Adjust if necessary.
•Make sure that operation is smooth.
Throttle grip•Check cable free play.
6-9, 6-15
•If necessary, have Yamaha dealer adjust cable free play
and lubricate cable and grip housing.
The 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
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4
PRE-OPERATION CHECKS
NOTE :
Pre-operation checks should be made each time the scooter is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved.
EWA00033
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the scooter.
ITEM CHECKS PAGE
•Check for damage.
Wheels and tires•Check tire condition and tread depth.
6-10 — 6-11
•Check air pressure.
•Correct if necessary.
Brake levers•Make sure that operation is smooth.
6-12, 6-15
•Lubricate lever pivoting points if necessary.
Centerstand•Make sure that operation is smooth.
6-16
•Lubricate pivot if necessary.
Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.
—
•Tighten if necessary.
Instruments, lights, signals•Check operation.
3-2 — 3-4
and switch•Correct if necessary.
Battery•Check fluid level.
6-18
•Fill with distilled water if necessary.
4-2

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PERIODIC MAINTENANCE AND MINOR REPAIR
Periodic maintenance and lubrication chart ............ 6-2
Removing and installing the panel .......................... 6-5
Panel A .................................................................... 6-5
Checking the spark plug ......................................... 6-5
Final transmission oil .............................................. 6-6
Cleaning the air filter element ................................. 6-7
Adjusting the carburetor .......................................... 6-9
Adjusting the throttle cable free play ....................... 6-9
Tires ...................................................................... 6-10
Cast wheels .......................................................... 6-11
Adjusting the front brake lever free play ................ 6-12
Adjusting the front brake lever free play ................ 6-12
Checking the front brake pads .............................. 6-13
and rear brake shoes
Checking the brake fluid level ............................... 6-14
6 Changing the brake fluid ....................................... 6-15
Checking and lubricating the throttle grip .............. 6-15
and cable
Lubricating the front and rear brakes levers .......... 6-15
Checking and lubricating the centerstand ............. 6-16
Checking the front fork .......................................... 6-16
Checking the steering ........................................... 6-17
Checking the wheel bearings ................................ 6-17
Battery ................................................................... 6-18
Replacing the fuse ................................................ 6-19
Replacing a headlight bulb .................................... 6-20
Replacing the brake taillight bulb .......................... 6-21
Replacing a turn signal light bulb .......................... 6-21
Troubleshooting ..................................................... 6-22
Troubleshooting chart ............................................ 6-23

PERIODIC MAINTENANCE AND MINOR REPAIR
6
1 * Fuel line•Check fuel hoses and vacuum hose for cracks or damage.√√√√ √
2 Spark plug•Replace.√√√√ √
3 Air filter element•Clean.√√•Replace.√√
4 * Battery•Check electrolyte level and specific gravity.
√√√√ √
•Make sure that the breather hose is properly routed.
•Check operation, fluid level and vehicle for fluid leak
√√√√√ √
5 * Front brake(See NOTE on page 6-4.)
•Replace brake pads. Whenever worn to the limit
6 * Rear brake•Check operation and adjust brake lever free play.√√√√√ √•Replace brake shoes. Whenever worn to the limit
7 * Brake hose•Check for cracks or damage.√√√√ √•Replace. (See NOTE on page 6-4.) Every 4 years
8 * Wheels•Check runout and for damage.√√√√
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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 30,000 km, repeat the maintenance intervals starting from 6,000 km.
•Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
ODOMETER READING (x 1,000 km)
NO. ITEMCHECK OR MAINTENANCE JOB
1
ANNUAL
CHECK
6121824
6-2

PERIODIC MAINTENANCE AND MINOR REPAIR
6
21 Moving parts and cables•Lubricate.√√√√ √
22 * Lights, signals and•Check operation.
√√√√√ √
switches•Adjust headlight beam.
ODOMETER READING (x 1,000 km)
NO. ITEMCHECK OR MAINTENANCE JOB
1
ANNUAL
CHECK
6121824
EAU03541*
NOTE :
•The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
•Hydraulic brake service
•Regularly check and, if necessary, correct the brake fluid level.
•Every two years change the brake fluid.
•Replace the brake hoses every four years and if cracked or damaged.
6-4

PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Checking the brake fluid
level
Insufficient brake fluid may allow air to
enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake
system for leakage.Observe these precautions:
•When checking the fluid level,
make sure that the top of the
master cylinder is level by turning
the handlebars.
•Use only the recommended
quality brake fluid, otherwise the
rubber seals may deteriorate,
causing leakage and poor braking
performance.
Recommended brake fluid:
DOT 4
NOTE :
If DOT 4 is not available, DOT 3 can be
used.
•Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
•Be careful that water does not
enter the master cylinder when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
•Brake fluid may deteriorate
painted surfaces or plastic parts.
Always clean up spilled fluid
immediately.
•As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
1
ZAUM0377
1. Brake fluid level
6-14

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAUM0008
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and
lubrication chart. In addition, have the
brake hose replaced every four years
or whenever it is damaged or leaking.
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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.
6-15
ZAUM0061
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Adjusting the Autolube pump
The Autolube pump is a vital and
sophisticated component of the engine,
which must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
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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)

SCOOTER CARE AND STORAGE
7
Care
While the open design of a scooter
reveals the attractiveness of the
technology, it also makes it more
vulnerable. Rust and corrosion can
develop even if high-quality
components are used. A rusty exhaust
pipe may go unnoticed on a car,
however, it detracts from the overall
appearance of a scooter. Frequent and
proper care does not only comply with
the terms of the warranty, but it will also
keep your scooter looking good, extend
its life and optimize its performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly
installed.3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such
products onto seals, gaskets and
wheel axles. Always rinse the dirt
and degreaser off with water.
Cleaning
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•Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the
affected area any longer than
instructed. Also, thoroughly
rinse the area off with water,
immediately dry it, and then
apply a corrosion protection
spray.
•Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.
•Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust
removers or inhibitors, brake
fluid, antifreeze or electrolyte.
•Do not use high-pressure
washers or steam-jet cleaners
since they cause water seepage
and deterioration in the following
areas: seals (of wheel and
swingarm bearings, fork and
brakes), electric components
(couplers, connectors, instru-
ments, switches and lights),
breather hoses and vents.
7-1