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PERIODIC MAINTENANCE AND MINOR REPAIR
ZAUM00**
1
1. BatteryTo install the battery
1. Connect the battery couplers, and
then place the battery in the origi-
nal position.
2. Install the battery holder bracket by
installing the bolt.
3. Install the panel by installing the
screw.
4. Fully charge the battery before in-
stallation.
EAUT1431
Replacing the fusesThe main fuse box is located behind
panel B. (See page 6-6.)ZAUM00**
1
1. Main fuseThe fuse block, which contains the fuses
for the individual circuits, is located in
the storage compartment. (See page 3-
8.)
ZAUM00**
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6
1. Lid
2. Fuse box
3. Carburetor heater fuse
4. Ignition fuse
5. Headlight fuse
6. Signaling system fuseIf a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
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PERIODIC MAINTENANCE AND MINOR REPAIR
Specified fuses:
Main fuse:
30 A
Headlight fuse:
15 A
Signaling system fuse:
15 A
Ignition fuse:
7.5 A
Carburetor heater fuse:
7.5 A
ECA10640
cCDo not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows again,
have a Yamaha dealer check the
electrical system.
EAU23710
Replacing a headlight bulbThis model is equipped with quartz bulb
headlights. If a headlight bulb burns out,
replace it as follows.
1. Place the vehicle on the
centerstand.
2. Remove panel B. (See page 6-6.)
3. Disconnect the headlight coupler,
and then remove the bulb cover.ZAUM00**
1
1. Bulb cover4. Unhook the headlight bulb holder,
and then remove the defective bulb.
ZAUM00**
1
1. Headlight bulb holder
EWA10790
wHeadlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.5. Place a new headlight bulb into po-
sition, and then secure it with the
bulb holder.
ECA10660
cCDo not touch the glass part of the
headlight bulb to keep it free from oil,
otherwise the transparency of the
glass, the luminosity of the bulb, and
5ML-F8199-E1ch6.pmd2004/10/04, 20:08 26
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PERIODIC MAINTENANCE AND MINOR REPAIR
the bulb life will be adversely affected.
Thoroughly clean off any dirt and fin-
gerprints on the headlight bulb us-
ing a cloth moistened with alcohol
or thinner.6. Install the headlight bulb cover, and
then connect the coupler.
7. Install the panel.
8. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU24131
Replacing the tail/brake light
bulb1. Remove the tail/brake light lens by
removing the screws.
2. Remove the defective bulb by push-
ing it in and turning it counterclock-
wise.ZAUM00**
1
1. Bulb3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screws.
ECA10680
cCDo not overtighten the screws, other-
wise the lens may break.
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAUT1360
Replacing a front turn signal
light bulb
ECA10670
cCIt is advisable to have a Yamaha dealer
perform this job.1. Place the scooter on the
centerstand.
2. Remove panel A. (See page 6-6.)
3. Remove the socket (together with
the bulb) by turning it counterclock-
wise.
4. Remove the defective bulb by push-
ing it in and turning it counterclock-
wise.ZAUM00**
2 1
1. Socket
2. Turn signal light bulb
5. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
6. Install the socket (together with the
bulb) by turning it clockwise.
7. Install the panel.
EAUT1330
Rear turn signal light bulbIf a rear turn signal light does not come
on, have a Yamaha dealer check the
electrical circuit or replace the bulb.
5ML-F8199-E1ch6.pmd2004/10/04, 20:08 28
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SCOOTER CARE AND STORAGE
EAU26090
CareWhile the open design of a scooter re-
veals the attractiveness of the technol-
ogy, 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 over-
all 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 plas-
tic bag after the engine has cooled
down.
2. Make sure that all caps and cov-
ers 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 prod-ucts onto seals, gaskets and wheel
axles. Always rinse the dirt and
degreaser off with water.
Cleaning
ECA10780
cC8 88 8
8Avoid 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.
8 88 8
8Improper 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.
8 88 8
8Do 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 prod-ucts, solvent or thinner, fuel
(gasoline), rust removers or in-
hibitors, brake fluid, antifreeze or
electrolyte.
8 88 8
8Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and
swingarm bearings, fork and
brakes), electric components
(couplers, connectors, instru-
ments, switches and lights),
breather hoses and vents.
8 88 8
8For scooters equipped with a
windshield: Do not use strong
cleaners or hard sponges as they
will cause dulling or scratching.
Some cleaning compounds for
plastic may leave scratches on
the windshield. Test the product
on a small hidden part of the
windshield to make sure that it
does not leave any marks. If the
windshield is scratched, use a
quality plastic polishing com-
pound after washing.
EAU25990
SCOOTER CARE AND STORAGE
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SPECIFICATIONSFront tireType
Tubeless
Size
110 / 70-12 47L
Manufacturer/model
CHENG SHIN / C-922N-47LRear tireType
Tubeless
Size
120 / 70-12 58L
Manufacturer/model
CHENG SHIN / C-6007-58L
Maximum load
170 kg
(Total weight of rider, passenger, cargo and ac-
cessories)Tire air pressure (measured on cold tires)Loading condition
0-90 kg
Front
175 kPa
Rear
200 kPa
Loading condition
90-170 kg
Front
200 kPa
Rear
225 kPaFront wheelWheel type
Cast wheel
Rim size
12xMT2.75
Rear wheelWheel type
Cast wheel
Rim size
12xMT3.00Front brakeType
Single disc brake
Operation
Right hand operation
Recommended fluid
DOT 4Rear brakeType
Drum brake
Operation
Left hand operationFront suspensionType
Telescopic fork
Spring/shock absorber type
Coil spring/oil damper
Wheel travel
90.0 mmRear suspensionType
Unit swing
Spring/shock absorber type
Coil spring/oil damper
Wheel travel
95.0 mm
Electrical systemIgnition system
C.D.I.
Charging system
A.C. magnetoBatteryModel
YTX7A-BS
Voltage, capacity
12 V, 6.0 AhHeadlightBulb type
Halogen bulbBulb voltage, wattage x quantityHeadlight
12 V, 60 W/55.0 W x 1
Tail/brake light
12 V, 5.0/21.0 W x 1
Front turn signal light
12 V, 10.0 W x 2
Rear turn signal light
12 V, 16.0 W x 2
Auxiliary light
12 V, 5.0 W x 1
Meter lighting
12 V, 1.7 W x 3
High beam indicator light
12 V, 1.7 W x 1
Turn signal indicator light
12 V, 3.4 W x 1
5ML-F8199-E1ch8.pmd2004/10/04, 20:09 2
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SPECIFICATIONS
FusesMain fuse
30.0 A
Headlight fuse
15.0 A
Signaling system fuse
15.0 A
Ignition fuse
7.5 A
Carburetor heater fuse
7.5 A
5ML-F8199-E1ch8.pmd2004/10/04, 20:09 3
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INDEXAAcceleration and deceleration.................. 5-2
Air filter and V-belt case air filter
elements................................................6-11BBattery.....................................................6-23
Brake fluid level, checking ......................6-19
Brake fluid, changing ..............................6-20
Brake lever, front ...................................... 3-4
Brake lever, rear....................................... 3-4
Brake levers, lubricating.........................6-21
Brake pads and shoes, checking..........6-18
Braking...................................................... 5-2CCables, checking and lubricating ...........6-20
Carburetor,adjusting...............................6-13
Catalytic converter................................... 3-6
Centerstand and sidestand, checking and lu-
bricating.................................................6-21DDimmer switch.......................................... 3-4EEngine break-in ......................................... 5-3
Engine oil and oil strainer .......................... 6-8FFinal transmission oil ..............................6-10
Front brake lever free play, checking....6-17
Fuel........................................................... 3-6
Fuel consumption, tips for reducing ......... 5-3
Fuel gauge ................................................ 3-3
Fuel tank cap ............................................ 3-5
Fuses, replacing.....................................6-25
HHandlebar switches.................................. 3-3
Headlight bulb, replacing........................6-26
Helmet holder............................................ 3-8
High beam indicator light .......................... 3-2
Horn switch............................................... 3-4IIdentification numbers.............................. 9-1
Indicator lights........................................... 3-2KKey identification number......................... 9-1
Kickstarter................................................ 3-7LLuggage hook........................................... 3-9MMain switch/steering lock......................... 3-1
Model label................................................ 9-2PPanels, removing and installing................ 6-6
Parking...................................................... 5-4
Part locations............................................ 2-1
Periodic maintenance and lubrication
chart ........................................................ 6-3
Pre-operation check list........................... 4-2
Rear brake lever free play, adjusting .....6-18SSafe-riding points...................................... 1-4
Safety information..................................... 1-1
Seat ........................................................... 3-7
Sidestand................................................3-10
Sidestand switch operation check .........3-10Spark plug, checking................................ 6-7
Specifications............................................ 8-1
Speedometer unit..................................... 3-3
Start switch............................................... 3-4
Starting a cold engine ............................... 5-1
Starting off ................................................. 5-2
Storage...................................................... 7-3
Storage compartment............................... 3-8
TTail/brake light bulb, replacing ................6-27
Throttle cable free play, adjusting..........6-14
Throttle grip and cable, checking and lubricat-
ing ..........................................................6-21
Tires........................................................6-15
Tool kit ....................................................... 6-1
Troubleshooting......................................6-29
Troubleshooting chart.............................6-30
Turn signal indicator light.......................... 3-2
Turn signal light bulb (front), replacing ...6-28
Turn signal switch ..................................... 3-4VValve clearance......................................6-14
Vehicle identification number .................... 9-1WWheel bearings, checking ......................6-23
Wheels....................................................6-17
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