Page 49 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6
ab
ZAUM0320To increase the brake lever free play,
turn the adjusting nut at the brake shoe
plate in direction a . To decrease the
brake lever free play, turn the adjusting
nut in direction b .
EW000101
If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make thisadjustment.
EAU00720
Checking the front brake
pads and rear brake shoesThe front brake pads and the rear brake
shoes must be checked for wear at the
intervals specified in the periodic main-
tenance and lubrication chart.
EAU01436
Front brake pads
Check each front brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 3.1 mm, have a
Yamaha dealer replace, the brake pads
as a set.
a
ZAUM0243a. Wear limit
6-12
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04502
Rear brake shoes
The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to
disassemble the brake. To check the
brake shoe wear, check the position of
the wear indicator while applying the
brake. If a brake shoe has worn to the
point that the wear indicator reaches
the wear limit line, have a Yamaha dea-
ler replace the brake shoes as a set.
1
2
ZAUM00591. Wear indicator
2. Wear limit
1
ZAUM05271. Minimum level mark
6-13
EAU00732
Checking the brake fluid levelInsufficient 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 perfor-
mance.
Recommended brake fluid:
DOT 4
NOTE :
If DOT 4 is not available, DOT 3 can beused.•
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 en-
ter the master cylinder when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAUM0008
Changing the brake fluidHave 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.
EAU02962
Checking and lubricating the
cablesThe 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 dealer 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 unsafeconditions.
6-14
•
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.
Page 52 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04034
Checking and lubricating the
throttle grip and cableThe 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.
ZAUM0061
EAU03118
Lubricating the front and rear
brake leversThe 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)
EAU04123
Checking and lubricating the
centerstandThe operation of the centerstand should
be checked before each ride, and the
pivots and metal-to-metal contact sur-
faces should be lubricated if necessary.
EWA00055
If the centerstand does not move up
and down smoothly, have a Yamahadealer check or repair it.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
1
ZAUM04551. Centerstand
6-15
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU02939
Checking the front forkThe condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
Securely support the scooter so thatthere is no danger of it falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.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 orrepair it.ZAUM0528
EAU00794
Checking the steeringWorn 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 thatthere is no danger of it falling over.
6-16
Page 54 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
62. 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.
ZAUM0160
EAU01144
Checking the wheel bearingsThe front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and
lubrication chart. If there is play in the
wheel hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
32 1
ZAUM0162
6-171. Panel A
2. Fuse
3. Battery
EAUM0049
BatteryA poorly maintained battery will corrode
and discharge quickly. The electrolyte
level, battery lead connections and
breather hose routing should be
checked before each ride and at the
intervals specified in the periodic main-
tenance and lubrication chart.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
1
2
+
UPPER
LOWER
ZAUM01061. Maximum level
2. Minimum level
6-18To check the electrolyte level
1. Place the scooter on a level sur-
face and hold it in an upright po-
sition.NOTE :
Make sure that the scooter is positioned
straight up when checking theelectrolyte level.
2. Remove panel A.
3. Check the electrolyte level in the
battery.
NOTE :
The electrolyte should be between theminimum and maximum level marks.
4. If the electrolyte is at or below the
minimum level mark, add distilled
water to raise it to the maximum
level mark.
EW000116
•
Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes
severe burns. Avoid any contact
with skin, eyes or clothing and
always shield your eyes when
working near batteries. In case of
contact, administer the following
FIRST AID.•
EXTERNAL: Flush with plenty of
water.
•
INTERNAL: Drink large
quantities of water or milk and
immediately call a physician.
•
EYES: Flush with water for 15
minutes and seek prompt
medical attention.
•
Batteries produce explosive
hydrogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and
provide sufficient ventilation
when charging it in an enclosed
space.
•
KEEP THIS AND ALL BATTERIES
OUT OF THE REACH OFCHILDREN.
EC000100
Use only distilled water, as tap water
contains minerals that are harmfulto the battery.
5. Check and, if necessary, tighten
the battery lead connections and
correct the breather hose routing.
Page 56 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6
1. Panel A
2. Fuse
3. Battery
6-1932 1
ZAUM0162
To store the battery
1. If the scooter will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
2. If the battery will be stored for
more than two months, check the
specific gravity of the electrolyte
at least once a month and fully
charge the battery whenever
necessary.
3. Fully charge the battery before
installation.
4. After installation, make sure that
the battery leads are properly
connected to the battery terminals
and that the breather hose is
properly routed, in good condition,
and not obstructed.
EC000099
If the breather hose is positioned in
such a way that the frame is exposed
to electrolyte or gas expelled from
the battery, the frame could sufferstructural and external damages.
EAU00809
Replacing the fuseThe fuse holder is located beside the
battery compartment behind panel A.
If the fuse is blown, replace it as follows.
1. Turn the key to “
” and turn off
all electrical circuits.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
Specified fuse:
7 A
EC000103
Do not use a fuse of a higher
amperage rating than recommended
to avoid causing extensive damage
to the electrical system and possiblya fire.
3. Turn the key to “
” and turn on
the electrical circuits to check if the
devices operate.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
