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8
Hydraulic brake service
• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required.
• Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
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8
EAU18752
Removin g an d installin g the
panelThe panel shown needs to be removed
to perform some of the maintenance
jobs described in this chapter. Refer to
this section each time the panel needs
to be removed and installed.
EAU78530
Panel A
To remove the panelRemove the screws, and then pull the
panel outward and slide it forward as
shown. To install the panel
Place the panel in the original position,
and then install the screws.
1. Panel AZAUM1938
1
1. Screw
1. Panel AZAUM19391
1
ZAUM1940
1
ZAUM1941
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8
EAU19623
Checkin g the spark plugThe spark plug is an important engine
component, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
it should be removed and checked in
accordance with the periodic mainte-
nance and lubrication chart. In addi-
tion, the condition of the spark plug
can reveal the condition of the engine.
The porcelain insulator around the
center electrode of the spark plug
should be a medium-to-light tan (the
ideal color when the vehicle is ridden
normally). If the spark plug shows a
distinctly different color, the engine
could be operating improperly. Do not
attempt to diagnose such problems
yourself. Instead, have a Yamaha deal-
er check the vehicle.
If the spark plug shows signs of elec-
trode erosion and excessive carbon or
other deposits, it should be replaced. Before installing a spark plug, the
spark plug gap should be measured
with a wire thickness gauge and, if
necessary, adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the spark
plug threads.
TIPIf a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is 1/4–
1/2 turn past finger tight. However, the
spark plug should be tightened to the
specified torque as soon as possible.
Specifie
d spark plu g:
NGK/CPR8EA-9
1. Spark plug gap
Spark plu g g ap:
0.8–0.9 mm (0.031–0.035 in)
Ti ghtenin g torque:
Spark plug: 12.5 N·m (1.25 kgf·m, 9.22 lb·ft)
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EAU36113
CanisterThis model is equipped with a canister
to prevent the discharging of fuel vapor
into the atmosphere. Before operating
this vehicle, make sure to check the
following:
Check each hose connection.
Check each hose and canister for
cracks or damage. Replace if
damaged.
Make sure that the canister
breather is not blocked, and if
necessary, clean it.
EAU66995
Engine oil an d oil strainerThe engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil strainer
cleaned at the intervals specified in the
periodic maintenance and lubrication
chart.
To check the en gine oil level
1. Place the vehicle on the center- stand. A slight tilt to the side can
result in a false reading.
2. Start the engine, warm it up for several minutes, and then turn it
off.
3. Wait a few minutes until the oil set- tles, remove the engine oil filler
cap, wipe the engine oil dipstick
clean, insert it back into the oil fill-
er hole (without screwing it in), and
then remove it again to check the
oil level. WARNING! The muffler
an d muffler protector become
very hot d uring use. To avoi d
possi ble burns, let the muffler
an d protector cool before re-
movin g the oil filler cap.
[EWA17810]
1. Canister
2. Canister breather hoseZAUM1942
2 2
1
22
1
2
ZAUM1458
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8
TIPThe engine oil should be between the
tip of the dipstick and the maximum
level mark.4. If the engine oil is not between the
tip of the dipstick and the maxi-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Insert the dipstick into the oil filler hole, and then tighten the oil filler
cap. To chan
ge the en gine oil an d clean
the oil strainer 1. Start the engine, warm it up for several minutes, and then turn it
off.
2. Place an oil pan under the engine to collect the used oil.
3. Remove the engine oil filler cap and engine oil drain bolts A and B
to drain the oil from the crankcase.
NOTICE: When removin g the
en gine oil d rain bolt B, the O-
rin g, compression sprin g, an d
oil strainer will fall out. Take
care not to lose these parts.
[ECAT1022]
4. Clean the engine oil strainer with solvent, and then check it for
damage and replace it if neces-
sary.
5. Install the engine oil strainer, com- pression spring, new O-ring and
engine oil drain bolt B.TIPMake sure that the O-ring is properly
seated.
1. Oil filler hole
2. O-ring
3. Engine oil dipstick
4. Maximum level mark
5. Tip of the engine oil dipstickZAUM1943
3245
1 1
1
1. Engine oil drain bolt A
2. Gasket
3. Oil strainer
4. Compression spring
5. O-ring
6. Engine oil drain bolt BZAUM1944
2 3
4
5
6
1
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Periodic maintenance an d a djustment
8-12
8 6. Install engine oil drain bolt A and
its new gasket, and then tighten
both drain bolts to their specified
torques.
7. Refill with the specified amount of the recommended engine oil, and
then install and tighten the oil filler
cap.
TIPBe sure to wipe off spilled oil on any
parts after the engine and exhaust sys-
tem have cooled down.NOTICE
ECA24060
Make sure that no forei gn material
enters the crankcase.
8. Start the engine, and then let it idle for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
9. Turn the engine off, and then check the oil level and correct it if
necessary.
10. Reset the oil change tripmeter and oil change indicator “OIL”. (See
page 5-7 for reset procedures.)
EAU20067
Final transmission oilThe final transmission case must be
checked for oil leakage before each
ride. If any leakage is found, have a
Yamaha dealer check and repair the scooter. In addition, the final transmis-
sion oil must be changed as follows at
the intervals specified in the periodic
maintenance and lubrication chart. 1. Start the engine, warm up the final transmission oil by riding the
scooter for several minutes, and
then stop the engine.
2. Place the scooter on the center- stand.
3. Place an oil pan under the final transmission case to collect the
used oil.
4. Remove the final transmission oil filler cap and its O-ring from the fi-
nal transmission case.
Tightenin g torque:
Engine oil drain bolt A: 20 N·m (2.0 kgf·m, 15 lb·ft)
Engine oil drain bolt B:
20 N·m (2.0 kgf·m, 15 lb·ft)
Recommen ded en gine oil:
See page 10-1.
Oil quantity: 0.90 L (0.95 US qt, 0.79 Imp.qt)
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8
5. Remove the final transmission oil
drain bolt and its gasket to drain
the oil from the final transmission
case. 6. Install the final transmission oil
drain bolt and its new gasket, and
then tighten the bolt to the speci-
fied torque.
7. Refill with the specified amount of the recommended final transmis-
sion oil. WARNING! Make sure
that no forei gn material enters
the final transmission case.
Make sure that no oil gets on
the tire or wheel.
[EWA11312]
8. Install the final transmission oil fill- er cap and its new O-ring, and
then tighten the oil filler cap.
9. Check the final transmission case for oil leakage. If oil is leaking,
check for the cause.
EAUS1203
CoolantThe coolant level should be checked
regularly. In addition, the coolant must
be changed at the intervals specified in
the periodic maintenance chart.TIPIf genuine Yamaha coolant is not avail-
able, use an ethylene glycol antifreeze
containing corrosion inhibitors for alu-
minum engines and mix with distilled
water at a 1:1 ratio.
EAUM4331
To check the coolant level1. Place the vehicle on the center- stand.
1. Final transmission oil filler cap
2. O-ring
1. Final transmission oil drain bolt
2. GasketZAUM1945
1
2
ZAUM1946
12
Ti ghtenin g torque:
Final transmission oil drain bolt: 20 N·m (2.0 kgf·m, 15 lb·ft)
Recommen ded final transmission
oil: See page 10-1.
Oil quantity: 0.10 L (0.11 US qt, 0.09 Imp.qt)
Recommen ded coolant:
YAMALUBE coolant
Coolant quantity: Coolant reservoir (max level mark): 0.13 L (0.14 US qt, 0.11 Imp.qt)
Radiator (including all routes): 0.46 L (0.49 US qt, 0.40 Imp.qt)
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8
TIP The coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.2. Check the coolant level in the
coolant reservoir.TIPThe coolant should be between the mi-
nimum and maximum level marks.
3. If the coolant is at or below the mi-nimum level mark, have a Yamaha
dealer add coolant to the reser-
voir.
EAU33032
Chan gin g the coolant
The coolant must be changed at the in-
tervals specified in the periodic main-
tenance and lubrication chart. Have a
Yamaha dealer change the coolant.
WARNING! Never attempt to remove the ra diator cap when the en gine is
hot.
[EWA10382] EAU67174
Air filter an
d V- belt case air fil-
ter elementsThe air filter element should be re-
placed and the V-belt case air filter el-
ement should be cleaned at the
intervals specified in the periodic main-
tenance and lubrication chart. Service
the air filter elements more frequently if
you are riding in unusually wet or dusty
areas. The air filter check hose and V-
belt case air filter check hose must be
frequently checked and cleaned if nec-
essary.
Cleanin g the air filter check hose
1. Coolant level check window
2. Maximum level mark
3. Minimum level markZAUM1947
1 2
2
3 2
3
Coolant reservoir capacity (up to
the maximum level mark): 0.13 L (0.14 US qt, 0.11 Imp.qt)
1. Air filter check hoseZAUM1948
1 11
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