4
PRE-OPERATION CHECKS
ITEM CHECKS PAGE
NOTE :
Pre-operation checks should be made each time the scooter is used. Such an inspection can be accomplished in a veryshort 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 operatingthe scooter.
4-2 •Check for damage.
Wheels and Tires•Check tire condition and tread depth.
6-9 — 6-10
•Check air pressure.
•Correct if necessary.
Brake levers•Make sure that operation is smooth.
3-4 — 3-5•Lubricate lever pivoting points if necessary.
Centerstand•Make sure that operation is smooth.
6-15•Lubricate pivot if necessary.
Chassis-fasteners•Make sure that all nuts, bolts and screws are properly tightened.
—•Tighten if necessary.
Instruments, lights•Check operation.
3-1 — 3-4, 6-20 — 6-21
signals and switches•Correct if necessary.
Battery•Check fluid level.
6-17
•Fill with distilled water if necessary.
EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR
Periodic maintenance and lubrication chart ............ 6-2
Checking the spark plug ......................................... 6-5
Final transmission oil .............................................. 6-6
Cleaning the air filter element ................................. 6-7
Adjusting the carburetor .......................................... 6-8
Adjusting the throttle cable free play ....................... 6-8
Tires ........................................................................ 6-9
Cast wheels .......................................................... 6-11
Adjusting the front brake lever free play ............... 6-11
Adjusting the rear brake lever free play ................ 6-11
Checking the front brake pads
and rear brake shoes ............................................ 6-12
Checking the brake fluid level ............................... 6-13
Changing the brake fluid ....................................... 6-14
Checking and lubricating the cables ..................... 6-14
6 Checking and lubricating the throttle grip
and cable .............................................................. 6-15
Lubricating the front and rear brake levers ........... 6-15
Checking and lubricating the centerstand ............. 6-15
Checking the front fork .......................................... 6-16
Checking the steering ........................................... 6-16
Checking the wheel bearings ................................ 6-17
Battery ................................................................... 6-17
Replacing the fuse ................................................ 6-19
Replacing a headlight bulb .................................... 6-20
Replacing a front turn signal light bulb .................. 6-21
Replacing a rear turn signal light bulb or
the tail/brake light bulb .......................................... 6-21
Troubleshooting .................................................... 6-21
Troubleshooting chart ........................................... 6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
6
6-3 •Check tread depth and for damage.
9 * Tires•Replace if necessary.
•Check air pressure.√√√√ √
•Correct if necessary.
10 * Wheel bearings•Check bearing for looseness or damage.√√√√11 * Steering bearings•Check bearing play and steering for roughness.√√√√√
•Lubricate with lithium-soap-based grease.Every 24,000 km
12 * Chassis fasteners•Make sure that all nuts, bolts and screws
√√√√ √are properly tightened.
13 Centerstand•Check operation.
√√√√ √•Lubricate.
14 * Front fork•Check operation and for oil leakage.√√√√
15 * Rear shock absorber
•Check operation and shock absorber for oil leakage.√√√√
assembly
16 * Carburetor•Adjust engine idling speed.√√√√√ √
17 * Autolube pump•Check operation.
√√√√
•Bleed if necessary.
18 Final transmission oil•Check vehicle for oil leakage.√√ √
•Change.√√√
19 * V-belt•Replace.Every 10,000 kmNO. Item
Check or maintenance job
ODOMETER READING (x 1,000 km)1ANNUAL
CHECK
6121824
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04551*
TiresTo 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.ZAUM0053
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 accessoriesapproved for this model.
EW000077
Because loading has an enormous
impact on the handling, braking, per-
formance and safety characteristics of
your scooter, you should keep the
following precautions in mind.•
NEVER OVERLOAD THE SCOO-
TER! Operation of an overloaded
scooter may result in tire damage,
loss of control, or severe injury.
Make sure that the total weight of
rider, cargo, and accessories
does not exceed the specified
maximum load for the vehicle.
•
Do not carry along loosely packed
items, which can shift during a
ride.
•
Securely pack the heaviest items
close to the center of the scooter
and distribute the weight evenly
on both sides.
•
Adjust the suspension and tire air
pressure with regard to the load.
Check the tire condition and airpressure before each ride.
Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg150 kPa
1.5 kgf/cm
2
1.5 bar150 kPa
1.5 kgf/cm
2
1.5 bar
90 kg load-maximum
150 kPa
1.5 kgf/cm
2
1.5 bar170 kPa
1.7 kgf/cm
2
1.7 bar
Maximum load* 184 kg
* Total weight of rider, passenger, cargo and
accessories
6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
6 Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail
or glass fragments in it, or if the sidewall
is cracked, have a Yamaha dealer re-
place the tire immediately.
EW000079
•
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
scooter with excessively worn
tires decreases riding stability
and can lead to loss of control.
•
The replacement of all wheel
and brake related parts,
including the tires, should be
left to a Yamaha dealer, who has
the necessary professionalknowledge and experience.
Minimum tire tread depth
(front and rear)1.6 mmNOTE :
The tire tread depth limits may differ
from country to country. Always complywith the local regulations.
1
2
ZAUM00541. Tread depth
2. Side wall
Tire information
This scooter is equipped with tubeless
tires.
6-10
MICHELIN
120/80-12 55L BOPPER
FrontManufacturer Size TypeRearCHENG SHIN
120/80-12 55J MAXXIS
MICHELIN
130/90-10 61L BOPPER
CHENG SHIN
130/90-10 61J MAXXIS
Manufacturer Size Type
SCOOTER CARE AND STORAGE
7After cleaning
1. Dry the scooter with a chamois or
an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally
induced discoloring of stainless-
steel exhaust systems can be
removed through polishing.)
3. To prevent corrosion, it is
recommended to apply a corro-
sion protection spray on all metal,
including chrome- and nickel-
plated, surfaces.
4. Use spray oil as a universal
cleaner to remove any remaining
dirt.
5. Touch up minor paint damage
caused by stones, etc.
6. Wax all painted surfaces.
7. Let the scooter dry completely
before storing or covering it.
EWA00002
•
Make sure that there is no oil
or wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild
detergent.
•
Before operating the scooter
test its braking performanceand cornering behavior.
ECA00013
•
Apply spray oil and wax
sparingly and make sure to
wipe off any excess.
•
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
•
Avoid using abrasive polishing
compounds as they will wearaway the paint.
NOTE :
Consult a Yamaha dealer for advice onwhat products to use.
7-3
SCOOTER CARE AND STORAGE
7
StorageShort-term
Always store your scooter in a cool, dry
place and, if necessary, protect it
against dust with a porous cover.
ECA00015
•
Storing the scooter in a poorly
ventilated room or covering it
with a tarp, while it is still wet,
will allow water and humidity to
seep in and cause rust.
•
To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strongchemicals are stored.Long-term
Before storing your scooter for several
months:
1. Follow all the instructions in the
"Care" section of this chapter.
2. Drain the carburetor float
chamber by loosening the drain
bolt; this will prevent fuel deposits
from building up. Pour the drained
fuel into the fuel tank.
3. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
4. Perform the following steps to
protect the cylinder, piston rings,
etc. from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine
oil into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit
sparking during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap.
EWA00003
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turningthe engine over.
5. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
6. Check and, if necessary, correct
the tire air pressure, and then lift
the scooter so that both of its
wheels are off the ground.
Alternatively, turn the wheels a
little every month in order to
prevent the tires from becoming
degraded in one spot.
7-4
SPECIFICATIONS
8
8-2 Tires:
Front:
Type Tubeless
Size / Manufacturer / model 120/80-12 55L / MICHELIN
/ BOPPER
120/80-12 55J / CHENG SHIN
/ MAXXIS
Rear:
Type Tubeless
Size / Manufacturer / model 130/90-10 61L / MICHELIN
/ BOPPER
130/90-10 61J / CHENG SHIN
/ MAXXIS
Maximum load * 184 kg
Air pressure (cold tire):
Up to 90 kg load*
Front 150 kpa
Rear 150 kpa
90 kg load—maximum load *
Front 150 kpa
Rear 170 kpa
* Total weight of rider, passenger, cargo and accessories
Minimum tire tread depth 1.6 mmWheels:
Front
Type Cast wheel/Aluminium
Size 12 X MT 2.75
Rear
Type Cast wheel/aluminium
Size 10 X MT 3.00
Brakes:
Front
Type Single disc brake
Operation Right hand operation
Type brake fluid DOT 4 or DOT 3
Rear
Type Drum brake
Operation Left hand operation
Suspension:
Front suspension Telescopic fork
Rear suspension Unit swing
Shock absorber:
Front fork type Coil spring/oil damper
Rear shock absorber Coil spring/oil damper
assembly type
Wheel travel:
Front wheel travel 104 mm
Rear wheel travel 100 mm