2006 YAMAHA VERSITY 300 Owners Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
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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 in-
stead.


From 50000 km, repeat the maintenance intervals starting from 10000 km.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
1*Fuel lineCheck fuel and vacuum hoses for cracks or damage.√√√√ √
2 Spark plugCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.√√
4 Air filter elementClean.√√
Replace.√√
5V-belt case air filter ele-
mentClean.√√√√
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
8*Brake hosesCheck for cracks or damage.√√√√ √
Replace. Every 4 years

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9*WheelsCheck runout and for damage.√√√√
10*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
11*Wheel bearingsCheck bearing for looseness or damage.√√√√
12*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20000 km
13*Chassis fastenersMake sure that all nuts, bolts and screws are properly
tightened.√√√√ √
14 Sidestand, centerstandCheck operation.
Lubricate.√√√√ √
15*Sidestand switchCheck operation.√√√√√ √
16*Front forkCheck operation and for oil leakage.√√√√
17*Shock absorber assem-
bliesCheck operation and shock absorbers for oil leakage.√√√√
18*CarburetorAdjust engine idling speed.√√√√√ √
19 Engine oilChange. (See page 3-4.)√When the oil change indicator comes on
(every 3000 km)
Check oil level and vehicle for oil leakage. Every 3000 km√
20*Engine oil strainerClean.√
21*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change. Every 3 years
22 Final transmission oilCheck vehicle for oil leakage.√√ √
Change.√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
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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.
23*V- b e l tReplace. Every 20000 km
24*Front and rear brake
switchesCheck operation.√√√√√ √
25Moving parts and ca-
blesLubricate.√√√√ √
26*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
27*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
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Removing and installing
cowlings and panels The cowlings and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each time
a cowling or panel needs to be re-
moved and installed.1. Cowling A
1
ZAUM0421
1. Cowling B
1. Windshield
2. Panel A
1
ZAUM0422
1
2
ZAUM0420
1. Panel B
1. Panel C
1
ZAUM0424
1
ZAUM0425

PERIODIC MAINTENANCE AND MINOR REPAIR
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6
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Cowling A
To remove the cowling1. Pull up the floorboard mat on each
side of the scooter.
2. Remove panel A. (See page 6-7.)
3. Remove the cowling screws.4. Disconnect the headlight coupler
and the turn signal coupler.
5. Pull the cowling off.To install the cowling
1. Connect the headlight coupler and
the turn signal coupler.
2. Place the cowling in the original
position, and then install the
screws.
3. Install the panel.
4. Place the floorboard mats in their
original position.
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Cowling B
To remove the cowling1. Pull up the floorboard mat on each
side of the scooter.
1. Panel D
1. Panel E
1
ZAUM0426
1
ZAUM0584
1. Cowling A
2. Screw
3. Floorboard mat
1. Turn signal light lead coupler
2. Headlight coupler
3 2 1
ZAUM0427
12
ZAUM0428
1. Floorboard mat
1
ZAUM0435

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
62. Remove the screws on each side
of scooter, and then take the cowl-
ing off.To install the cowling
1. Place the cowling in the original
position, and then install the
screws.
2. Place the floorboard mats in their
original position.
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Panel A
To remove the panel1. Remove the screws, and then take
the windshield off.
2. Remove the screws, and then pull
the panel out as shown.To install the panel
1. Place the panel in the original posi-
tion, and then install the screws.
2. Place the windshield in the original
position, and then install the
screws.
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Panel B
To remove the panelRemove the screw, and then pull the
panel off as shown.
1. Screw
2. Cowling B
1. Screw
2. Cowling B
2
1
ZAUM0430
1
2
ZAUM0429
1. Windshield
2. Screw
2 1
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1. Screw
2. Panel A1
2ZAUM0433

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6 To install the panel
Place the panel in the original position,
and then install the screw.
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Panel C
To remove the panel1. Pull up the right floorboard mat.2. Remove the panel as shown.
To install the panel
1. Place the panel in the original posi-
tion.
2. Place the floorboard mat in the
original position.
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Panel D
To remove the panelPull the panel off as shown.
To install the panelPlace the panel in the original position.
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Panel E
To remove the panelRemove the screw, and then pull the
panel off as shown.
1. Screw
2. Panel B
1
2
ZAUM0434
1. Floorboard mat
1. Panel C
1
ZAUM0435
1
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1. Panel D
1
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6To install the panel
Place the panel in the original position,
and then install the screw.
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Checking the spark plug The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug
1. Remove cowling B. (See page
6-6.)
2. Remove the spark plug cap.3. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
NOTE:If the spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have aYamaha dealer check the vehicle.
1. Panel E
2. Screw
1
2
ZAUM0585
1. Spark plug cap
1
ZAUM0438
1. Spark plug wrench
1
ZAUM0036