PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
WARNING
EWA10790
Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooleddown.
5. Place a new headlight bulb into po-
sition, and then install the bulb
holder by turning the holder clock-
wise.CAUTION:
ECA10660
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency ofthe glass, the luminosity of the bulb,
and the bulb life will be adversely af-
fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with al-
cohol or thinner.
6. Install the headlight bulb cover.
7. Install the cowling.
8. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAUT1260
Replacing a front turn signal
light bulb CAUTION:
ECA10670
It is advisable to have a Yamahadealer perform this job.
1. Place the scooter on the center-
stand.
2. Remove cowling A. (See page
6-6.)
3. Remove the socket (together with
the bulb) by turning it counter-
clockwise.
4. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
1. Headlight bulb holder
2. Headlight bulb
1
2
1. Do not touch the glass part of the bulb.
1. Turn signal light bulb socket
1
U4P7E1E0.book Page 26 Wednesday, December 12, 2007 9:37 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
65. 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 cowling.
EAU37741
Rear turn signal light and
tail/brake light If a rear turn signal light or the tail/brake
light does not come on, have a Yamaha
dealer check its electrical circuit or re-
place the bulb.
EAU45460
Replacing the auxiliary light
bulb If the auxiliary light bulb burns out, re-
place it as follows.
1. Place the vehicle on the center-
stand.
2. Remove cowling A. (See page
6-6.)
3. Remove the auxiliary light socket
(together with the bulb) by pulling it
out.
4. Remove the defective bulb by pull-
ing it out.
5. Insert a new bulb into the socket.1. Auxiliary light bulb
2. Auxiliary light bulb socket
12
U4P7E1E0.book Page 27 Wednesday, December 12, 2007 9:37 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6 6. Install the auxiliary light socket (to-
gether with the bulb) by pushing it
in.
7. Install the cowling.
EAU25860
Troubleshooting Although Yamaha scooters receive a
thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your scooter re-
quire any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the scooter prop-
erly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
U4P7E1E0.book Page 28 Wednesday, December 12, 2007 9:37 AM
SCOOTER CARE AND STORAGE
7-1
7
EAU37833
Matte color caution CAUTION:
ECA15192
Some models are equipped with
matte colored finished parts. Be
sure to consult a Yamaha dealer for
advice on what products to use be-
fore cleaning the vehicle. Using a
brush, harsh chemical products or
cleaning compounds when cleaning
these parts will scratch or damage
their surface. Wax also should not
be applied to any matte colored fin-ished parts.
EAU26091
Care While 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
overall appearance of a scooter. Fre-
quent 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 in-
stalled.
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 de-
greaser off with water.
Cleaning
CAUTION:
ECA10781
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 af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.
Improper cleaning can damage
plastic parts such as cowlings,
panels, windshields, headlight
lenses, meter lenses, etc. 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
U4P7E1E0.book Page 1 Wednesday, December 12, 2007 9:37 AM
SCOOTER CARE AND STORAGE
7-2
7cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
Do 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 swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.
For scooters equipped with a
windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound afterwashing.After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on the
roads during winter are extremely cor-
rosive in combination with water, carry
out the following steps after each ride in
the rain, near the sea or on salt-
sprayed roads.NOTE:Salt sprayed on roads in the winter mayremain well into spring.
1. Clean the scooter with cold water
and a mild detergent after the en-
gine has cooled down.
CAUTION:
ECA10790
Do not use warm water since it in-
creases the corrosive action of thesalt.
2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.
After 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 in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
3. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
4. Use spray oil as a universal clean-
er to remove any remaining dirt.
U4P7E1E0.book Page 2 Wednesday, December 12, 2007 9:37 AM
SPECIFICATIONS
8-2
8
Trail:
75.0 mm (2.95 in)Front tire:Type:
Tubeless
Size:
100/90-10 56J
Manufacturer/model:
CHENG SHIN/C-922Rear tire:Type:
Tubeless
Size:
100/90-10 56J
Manufacturer/model:
CHENG SHIN/C-940Loading:Maximum load:
167 kg (368 lb)
(Total weight of rider, passenger, cargo and
accessories)Tire air pressure (measured on cold
tires):Loading condition:
0–83 kg (0–183 lb)
Front:
175 kPa (25 psi) (1.75 kgf/cm²)
Rear:
200 kPa (29 psi) (2.00 kgf/cm²)
Loading condition:
83–167 kg (183–368 lb)
Front:
175 kPa (25 psi) (1.75 kgf/cm²)Rear:
250 kPa (36 psi) (2.50 kgf/cm²)
Front wheel:Wheel type:
Cast wheel
Rim size:
J10 x 2.15Rear wheel:Wheel type:
Cast wheel
Rim size:
J10 x MT2.50Front brake:Type:
Single disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 3 or 4Rear brake:Type:
Drum brake
Operation:
Left hand operationFront suspension:Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
80.0 mm (3.15 in)Rear suspension:Type:
Unit swingSpring/shock absorber type:
Coil spring/oil damper
Wheel travel:
65.0 mm (2.56 in)
Electrical system:Ignition system:
TCI (digital)
Charging system:
AC magnetoBattery:Model:
GTX7A-BS/YTX7A-BS
Voltage, capacity:
12 V, 6.0 AhHeadlight:Bulb type:
Halogen bulbBulb voltage, wattage × quantity:Headlight:
12 V, 35 W/35.0 W × 1
Tail/brake light:
12 V, 5.0 W/21.0 W × 1
Front turn signal light:
12 V, 10.0 W × 2
Rear turn signal light:
12 V, 16.0 W × 2
Meter lighting:
12 V, 3.4 W × 2
High beam indicator light:
12 V, 1.7 W × 1
Turn signal indicator light:
12 V, 1.7 W × 1
Engine trouble warning light:
12 V, 1.7 W × 1
U4P7E1E0.book Page 2 Wednesday, December 12, 2007 9:37 AM
INDEXAAcceleration and deceleration................. 5-3
Air filter and V-belt case air filter
elements ............................................. 6-12
Anti-theft alarm (optional)........................ 3-4
Auxiliary light bulb, replacing ................ 6-27BBattery................................................... 6-23
Brake fluid, changing ............................ 6-20
Brake fluid level, checking .................... 6-19
Brake lever, front..................................... 3-5
Brake lever, rear ..................................... 3-6
Brake levers, lubricating........................ 6-21
Brake pads and shoes, checking .......... 6-18
Braking .................................................... 5-3CCables, checking and lubricating .......... 6-20
Care ........................................................ 7-1
Carrier ................................................... 3-10
Catalytic converters ................................ 3-8
Centerstand and sidestand,
checking and lubricating ..................... 6-22
Cowlings and panels,
removing and installing ......................... 6-6DDimmer switch ........................................ 3-5EEngine break-in ....................................... 5-4
Engine oil ................................................ 6-9
Engine trouble warning light.................... 3-3FFinal transmission oil ............................ 6-11
Front brake lever free play, checking .... 6-17
Front fork, checking .............................. 6-22Fuel......................................................... 3-7
Fuel consumption, tips for reducing........ 5-4
Fuel gauge.............................................. 3-4
Fuel tank cap .......................................... 3-6
Fuse, replacing ..................................... 6-25
HHandlebar switches ................................ 3-5
Headlight bulb, replacing ...................... 6-25
Helmet holders ....................................... 3-9
High beam indicator light ........................ 3-2
Horn switch ............................................. 3-5IIdentification numbers ............................ 9-1
Ignition circuit cut-off system ................ 3-12
Indicator, indicator lights and
warning light ......................................... 3-2KKeyhole cover ......................................... 3-2
Key identification number ....................... 9-1LLuggage hook ....................................... 3-11MMain switch/steering lock........................ 3-1
Matte color, caution ................................ 7-1
Model label ............................................. 9-2PParking ................................................... 5-5
Part locations .......................................... 2-1
Periodic maintenance and lubrication
chart ..................................................... 6-2
Pre-operation check list .......................... 4-2RRear brake lever free play, adjusting .... 6-18Rear turn signal light and tail/brake
light ..................................................... 6-27
SSafe-riding points .................................... 1-4
Safety information ................................... 1-1
Seat ......................................................... 3-8
Self-diagnosis device .............................. 3-4
Sidestand .............................................. 3-11
Spark plug, checking ............................... 6-8
Specifications .......................................... 8-1
Speedometer unit .................................... 3-3
Starting off ............................................... 5-2
Starting the engine .................................. 5-1
Start switch.............................................. 3-5
Steering, checking................................. 6-23
Storage.................................................... 7-3
Storage compartments ............................ 3-9TThrottle cable free play, checking ......... 6-15
Throttle grip and cable,
checking and lubricating ..................... 6-21
Tires ...................................................... 6-15
Troubleshooting .................................... 6-28
Troubleshooting chart ........................... 6-29
Turn signal indicator light ........................ 3-2
Turn signal light bulb (front),
replacing ............................................. 6-26
Turn signal switch ................................... 3-5VValve clearance..................................... 6-15
Vehicle identification number .................. 9-1WWheel bearings, checking ..................... 6-23
Wheels .................................................. 6-17
U4P7E1E0.book Page 1 Wednesday, December 12, 2007 9:37 AM