1

OWNER’S MANUAL7
8

YJ125S
LIT-11626-17-43 5YR-F8199-10

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1

3
EAU10041

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 EAU10050

INTRODUCTION
EAU10090
Congratulations on your purchase of the Yamaha VINO125. This model is the result of Yamaha’s vast experience in the
production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and
reliability that have made Yamaha a leader in these fields.
1
This manual will give you an understanding of the operation, inspection, and basic maintenance of this scooter. If you have
any questions concerning the operation or maintenance of your scooter, please consult a Yamaha dealer. 2

The design and manufacture of this Yamaha scooter fully comply with the emissions standards for clean air applicable at the
3
date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of the
scooter. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the
recommended maintenance schedules and operating instructions contained within this manual. 4

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 EAU10120

IMPORTANT MANUAL INFORMATION

EAU34110
Particularly important information is distinguished in this manual by the following notations:

Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
1

2 Failure to follow WARNING instructions could result in severe injury or death to the scooter
w
operator, a bystander, or a person inspecting or repairing the scooter.
3
cC A CAUTION indicates special precautions that must be taken to avoid damage to the scooter.
4

5 NOTE: A NOTE provides key information to make procedures easier or clearer.

6 NOTE:
8 This manual should be considered a permanent part of this scooter and should remain with it even if the scooter is
7 subsequently sold.
8 Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most
current product information available at the time of printing, there may be minor discrepancies between your scooter and
8
this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.

9 EWA12410

w
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS SCOOTER.

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 IMPORTANT MANUAL INFORMATION
EAU10192

AFFIX DEALER 3

LABEL HERE 4

7
VINO125
OWNER’S MANUAL
©2003 by Yamaha Motor Taiwan Co., Ltd. 8
1st edition, November 2003
All rights reserved. 9
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Taiwan Co., Ltd.
is expressly prohibited.
Printed in Taiwan.
P/N LIT-11626-17-43

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TABLE OF CONTENTS
SAFETY INFORMATION ....... 1-1
Further safe-riding points ..... 1-5
Location of important labels .. 1-6
1 DESCRIPTION ....................... 2-1
Left view ............................... 2-1
2 Right view ............................. 2-2
Controls and instruments ..... 2-3
3 INSTRUMENT AND CONTROL
FUNCTIONS........................... 3-1
Main switch/steering lock ..... 3-1
4
Indicator lights ...................... 3-2
Handlebar switches .............. 3-2
5
Speedometer unit ................. 3-3
Fuel gauge ............................ 3-3
6 Front brake lever .................. 3-3
Rear brake lever ................... 3-4
7 Fuel tank cap ........................ 3-4
Fuel ...................................... 3-5
8 Catalytic converter ............... 3-5
Kickstarter ............................ 3-6
9 Seat ...................................... 3-6
Helmet holder ....................... 3-6
Storage compartment ........... 3-7
Luggage hook ....................... 3-8
Carrier .................................. 3-8
Sidestand ............................. 3-8
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Ignition circuit cut-off system 3-9
PRE-OPERATION CHECKS . 4-1
Pre-operation check list ........ 4-2
OPERATION AND IMPORTANT
RIDING POINTS .................... 5-1
Starting a cold engine ........... 5-1
Starting off ............................ 5-2
Acceleration and
deceleration ....................... 5-2
Braking ................................. 5-3
Engine break-in .................... 5-3
Parking ................................. 5-4
PERIODIC MAINTENANCE
AND MINOR REPAIR ............ 6-1
PERIODIC MAINTENANCE 6-1
Owner’s tool kit ..................... 6-1
Periodic maintenance chart for
the emission control
system ............................... 6-2
General maintenance and
lubrication chart ................. 6-3
Removing and installing
panels ................................ 6-6
Checking the spark plug ....... 6-7
Air filter and V-belt case air filter
elements ............................ 6-8
EAU10210
Replacing the tail/brake light
bulb .................................. 6-11
Replacing a turn signal light
bulb .................................. 6-11
Checking the front brake pads
and rear brake shoes ...... 6-12
Checking the brake fluid
level ................................. 6-13
Changing the brake fluid ..... 6-13
Checking and lubricating the
cables .............................. 6-14
Checking and lubricating the
throttle grip and cable ...... 6-14
Lubricating the front and rear
brake levers ..................... 6-14
Checking and lubricating the
centerstand and
sidestand ......................... 6-15
Checking the front fork ....... 6-15
Checking the steering ........ 6-16
Replacing the headlight
bulb .................................. 6-16
Final transmission oil .......... 6-17
Adjusting the carburetor ..... 6-19
Adjusting the throttle cable free
play .................................. 6-19
 TABLE OF CONTENTS
Tires ................................... 6-19
Cast wheels ....................... 6-21
Adjusting the brake lever free
play .................................. 6-21 1
Adjusting the rear brake lever
free play ........................... 6-21 2
Battery ................................ 6-22
Replacing the fuse .............. 6-23 3
Engine oil and oil strainer .... 6-24
Troubleshooting .................. 6-26 4
Troubleshooting chart ......... 6-27
SCOOTER CARE AND STOR-
5
AGE ........................................ 7-1
Care...................................... 7-1
6
Storage ................................. 7-3
SPECIFICATIONS ................. 8-1
CONSUMER INFORMATION 9-1 7
Identification numbers .......... 9-1
Reporting safety defects ...... 9-3 8
Motorcycle noise regulation .. 9-4
YAMAHA MOTOR CORPORA- 9
TION, U.S.A STREET AND
ENDURO MOTORCYCLE
LIMITED WARRANTY ....... 9-5
YAMAHA EXTENDED SER-
VICE (Y.E.S.) ..................... 9-7

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 EAU10220
Q SAFETY INFORMATION
EAU10260
Safe riding 8 Many accidents involve inexperi-
SCOOTERS ARE SINGLE TRACK VE-
8 Always make pre-operation checks. enced operators. In fact, many op-
HICLES. THEIR SAFE USE AND OP-
Careful checks may help prevent erators who have been involved in
ERATION ARE DEPENDENT UPON
an accident. accidents do not even have a cur-
1 THE USE OF PROPER RIDING TECH-
8 This scooter is designed to carry rent driver’s license.
NIQUES AS WELL AS THE EXPER-
the operator and passenger. 9 Make sure that you are quali-
2 TISE OF THE OPERATOR. EVERY OP-
8 The failure of motorists to detect fied and that you only lend your
ERATOR SHOULD KNOW THE FOL-
and recognize scooters in traffic is scooter to other qualified
LOWING REQUIREMENTS BEFORE
3 the predominating cause of auto- operators.
RIDING THIS SCOOTER.
mobile/scooter accidents. Many 9 Know your skills and limits.
HE OR SHE SHOULD:
accidents have been caused by an Staying within your limits may
4 8 OBTAIN THOROUGH INSTRUC-
automobile driver who did not see help you to avoid an accident.
TIONS FROM A COMPETENT
the scooter. Making yourself con- 9 We recommend that you
5 SOURCE ON ALL ASPECTS OF
spicuous appears to be very effec- practice riding your scooter
SCOOTER OPERATION.
tive in reducing the chance of this where there is no traffic until
8 OBSERVE THE WARNINGS AND
6 type of accident. you have become thoroughly
MAINTENANCE REQUIRE-
Therefore: familiar with the scooter and all
MENTS IN THE OWNER’S
9 Wear a brightly colored jacket. of its controls.
7 MANUAL.
9 Use extra caution when Many accidents have been caused
8 OBTAIN QUALIFIED TRAINING IN
approaching and passing by error of the scooter operator. A
8 SAFE AND PROPER RIDING
through intersections, since typical error made by the operator
TECHNIQUES.
intersections are the most is veering wide on a turn due to
8 OBTAIN PROFESSIONAL TECH-
9 likely places for scooter EXCESSIVE SPEED or
NICAL SERVICE AS INDICATED
accidents to occur. undercornering (insufficient lean
BY THE OWNER’S MANUAL AND/
9 Ride where other motorists can angle for the speed).
OR WHEN MADE NECESSARY
see you. Avoid riding in another 9 Always obey the speed limit
BY MECHANICAL CONDITIONS.
motorist’s blind spot. and never travel faster than
warranted by road and traffic
conditions.
1-1

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9 Always signal before turning or
changing lanes. Make sure that
other motorists can see you.
8 The posture of the operator and
passenger is important for proper
control.
9 The operator should keep both
hands on the handlebar and
both feet on the footboard
during operation to maintain
control of the scooter.
9 The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger foot-
rests.
9 Never carry a passenger unless
he or she can firmly place both
feet on the passenger foot-
rests.
8 Never ride under the influence of
alcohol or other drugs.
This scooter is designed for on-road
use only. It is not suitable for off-
road use.
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Q SAFETY INFORMATION
Protective apparel
The majority of fatalities from scooter
accidents are the result of head injuries.
The use of a safety helmet is the single
most critical factor in the prevention or
reduction of head injuries.
8 Always wear an approved helmet.
8 Wear a face shield or goggles. Wind
in your unprotected eyes could con-
tribute to an impairment of vision
which could delay seeing a hazard.
8 The use of a jacket, substantial
shoes, trousers, gloves, etc., is
effective in preventing or reducing
abrasions or lacerations.
8 Never wear loose-fitting clothes,
otherwise they could catch on the
control levers or wheels and cause
injury or an accident.
8 Never touch the engine or exhaust
system during or after operation.
They become very hot and can
cause burns. Always wear protec-
tive clothing that covers your legs,
ankles, and feet.
8 Passengers should also observe
the above precautions.
1-2
Modifications
Modifications made to this scooter not
approved by Yamaha, or the removal of
original equipment, may render the 1
scooter unsafe for use and may cause
severe personal injury. Modifications
may also make your scooter illegal to 2
use.
Loading and accessories 3
Adding accessories or cargo to your
scooter can adversely affect stability 4
and handling if the weight distribution of
the scooter is changed. To avoid the
possibility of an accident, use extreme 5
caution when adding cargo or accesso-
ries to your scooter. Use extra care when 6
riding a scooter that has added cargo or
accessories. Here are some general 7
guidelines to follow if loading cargo or
adding accessories to your scooter:
8
9
 Q SAFETY INFORMATION
Loading
The total weight of the operator, passen-
ger, accessories and cargo must not ex-
ceed the maximum load limit of 144 kg
1
(317 lb). When loading within this weight
limit, keep the following in mind:
2 8 Cargo and accessory weight should
be kept as low and close to the
3 scooter as possible. Make sure to
distribute the weight as evenly as
possible on both sides of the
4
scooter to minimize imbalance or
instability.
5 8 Shifting weights can create a sud-
den imbalance. Make sure that ac-
6 cessories and cargo are securely
attached to the scooter before riding.
Check accessory mounts and
7
cargo restraints frequently.
8 Never attach any large or heavy
8 items to the handlebar, front fork,
or front fender. Such items can cre-
9 ate unstable handling or a slow
steering response.
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Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this scooter. Since Yamaha cannot test
all other accessories that may be avail-
able, you must personally be responsible
for the proper selection, installation and
use of non-Yamaha accessories. Use
extreme caution when selecting and in-
stalling any accessories.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
8 Never install accessories or carry
cargo that would impair the perfor-
mance of your scooter. Carefully
inspect the accessory before us-
ing it to make sure that it does not
in any way reduce ground clear-
ance or cornering clearance, limit
suspension travel, steering travel
or control operation, or obscure
lights or reflectors.
9 Accessories fitted to the
handlebar or the front fork area
can create instability due to
improper weight distribution or
aerodynamic changes. If
1-3
accessories are added to the
handlebar or front fork area,
they must be as lightweight as
possible and should be kept to
a minimum.
9 Bulky or large accessories may
seriously affect the stability of
the scooter due to aerodynamic
effects. Wind may attempt to
lift the scooter, or the scooter
may become unstable in cross
winds. These accessories may
also cause instability when
passing or being passed by
large vehicles.
9 Certain accessories can
displace the operator from his
or her normal riding position.
This improper position limits
the freedom of movement of
the operator and may limit
control ability, therefore, such
accessories are not recom-
mended.
8 Use caution when adding electrical
accessories. If electrical accesso-
ries exceed the capacity of the
scooter’s electrical system an elec-

tric failure could result, which could
cause a dangerous loss of lights or
engine power.
Gasoline and exhaust gas
8 GASOLINE IS HIGHLY FLAM-
MABLE:
9 Always turn the engine off
when refueling.
9 Take care not to spill any
gasoline on the engine or
exhaust system when refueling.
9 Never refuel while smoking or
in the vicinity of an open flame.
8 Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of con-
sciousness and death within a
short time. Always operate your
scooter in an area that has adequate
ventilation.
8 Always turn the engine off before
leaving the scooter unattended and
remove the key from the main
switch. When parking the scooter,
note the following:
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Q SAFETY INFORMATION
9 The engine and exhaust
system may be hot, therefore,
park the scooter in a place
where pedestrians or children 1
are not likely to touch these hot
areas.
9 Do not park the scooter on a 2
slope or soft ground, otherwise
it may fall over. 3
9 Do not park the scooter near a
flammable source (e.g., a 4
kerosene heater, or near an
open flame), otherwise it could
catch fire. 5
8 If you should swallow any gasoline,
inhale a lot of gasoline vapor, or 6
allow gasoline to get into your eyes,
see your doctor immediately. If any 7
gasoline spills on your skin or cloth-
ing, immediately wash the affected
area with soap and water and 8
change your clothes.
9
1-4
 Q SAFETY INFORMATION
EAU10350
8 Braking can be extremely difficult is unstable. Use a strong cord to
Further safe-riding points on a wet road. Avoid hard braking, secure any luggage to the carriers.
because the scooter could slide. A loose load will affect the stability
Apply the brakes slowly when stop- of the scooter and could divert your
1
ping on a wet surface. attention from the road. (See page
8 Slow down as you approach a cor- 1-2.)
2 ner or turn. Once you have com-
pleted a turn, accelerate slowly.
3 8 Be careful when passing parked
cars. A driver might not see you and
open a door in your path.
4
8 Railroad crossings, streetcar rails,
ZAUM00**

Turn left iron plates on road construction

5 sites, and manhole covers become
extremely slippery when wet. Slow
6 down and cross them with caution.
Keep the scooter upright, otherwise
it could slide out from under you.
7
8 The brake lining could get wet when
you wash the scooter. After wash-
8 ing the scooter, check the brakes
before riding.
9 ZAUM00** 8 Always wear a helmet, gloves, trou-
sers (tapered around the cuff and
Turn right ankle so they do not flap), and a
bright colored jacket.
8 Make sure to signal clearly when 8 Do not carry too much luggage on
making turns. the scooter. An overloaded scooter

1-5

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 Q SAFETY INFORMATION
EAU10381

Location of important labels

Please read the following important labels carefully before operating this vehicle.
1

1 2 3 4
6
5
5
6

4 7

1-6

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 Q SAFETY INFORMATION

1 5
1

3 2
6
4

5 3

7 4

1-7

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 DESCRIPTION
EAU10410

Left view

2
4 5 6 7
3 3
2

4
1
5

7
8
8
1. Front wheel (page 6-19)
2. Front turn signal light (page 3-2) 11 10 9
3. Luggage hook (page 3-8) 9
4. Helmet holder (page 3-6)
5. Storage compartment (page 3-7)
6. Rear turn signal light (page 3-2)
7. Rear wheel (page 6-19)
8. Rear brake lever free play adjusting nut (page 6-21)
9. Kickstarter (page 3-6)
10.Air filter element (page 6-8)
11.Battery (page 6-22)
2-1

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 DESCRIPTION
EAU10420

Right view

3 12 13 14 15 16
17
4

7
18
8

12.Tail/brake light (page6-11)

9 13.Carrier (page3-8)
21 20 19
14.Fuel tank cap (page 3-4)
15.Seat (page 3-6)
16.Brake master cylinder (page 6-13)
17.Headlight (page 6-16)
18.Front brake caliper (page 6-12)
19.Spark plug (page 6-7)
20.Centerstand (page 6-15)
21.Muffler (page 3-5)
2-2

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 DESCRIPTION
EAU10430

Controls and instruments

2
24
25 3
23
22 4
26
5

6
29 28 27
7

9
22.Rear brake lever (page 3-4)
23.Left handlebar switches (page 3-2)
24.Speedometer unit (page 3-3)
25.Right handlebar switches (page 3-2)
26.Front brake lever (page 3-3)
27.Throttle grip (page 6-19)
28.Main switch / steering lock (page 3-1)
29.Fuel gauge (page 3-3)
2-3

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 INSTRUMENT AND CONTROL FUNCTIONS
EAU10460 EAU10680

Main switch/steering lock LOCK

1 The steering is locked, and all electrical
systems are off. The key can be re-
1 2 moved.

2 To lock the steering

1. Turn the handlebars all the way to
the left.
3 2. Push the key in from the “OFF” po-
ZAUM00**

sition, and then turn it to “LOCK”

4 ZAUM00** 1. Turn while still pushing it.
2. Release 3. Remove the key.
5 The main switch/steering lock controls EAU10530

the ignition and lighting systems, and is ON

used to lock the steering. The various
6 positions are described below.
To unlock the steering
All electrical circuits are supplied with
Push the key in, and then turn it to “OFF”
power, the taillight comes on, and the
while still pushing it.
engine can be started. The key cannot EWA10060

7 be removed. w
NOTE: Never turn the key to “OFF” or
1 The headlight and meter lighting come “LOCK” while the vehicle is moving,
8
on automatically when the engine is otherwise the electrical systems will
started. be switched off, which may result in
9 loss of control or an accident. Make
EAU10660
OFF sure that the vehicle is stopped be-
All electrical systems are off. The key fore turning the key to “OFF” or
ZAUM00**
can be removed. “LOCK”.
1. Push

3-1

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 INSTRUMENT AND CONTROL FUNCTIONS
EAU10980 EAU12342 EAU12660

Indicator lights Handlebar switches Engine stop switch “# #/$$”

EAU12400
EAU11020 Set this switch to “#” before starting
Turn signal indicator light “5 5” Dimmer switch “% %/&&”
the engine. Set this switch to “$” to stop
This indicator light flashes when the turn Set this switch to “&” for the high beam 1
the engine in case of an emergency, such
signal switch is pushed to the left or right. and to “%” for the low beam.
as when the motorcycle overturns or
when the throttle cable is stuck. 2
40
1
30
60
50
2 2
1 20
40
80

100
60 1 3
20
120 70
10 0

0 80

4
MPH

3
5
ZAUM00**
ZAUM00** 2
6
1. High beam indicator light ”&” 1. Dimmer switch “%/&“ ZAUM00**

2. Turn indicator light “5” 2. Turn signal switch “4/6”

3. Horn switch “*” 1. Engine stop switch “#/$“ 7
EAU11080 EAU12460 2. Start switch “,”
High beam indicator light “& &” Turn signal switch “4 4/6 6” EAU12700

This indicator light comes on when the To signal a right-hand turn, push this Start switch “,,” 8
high beam of the headlight is switched switch to “4”. To signal a left-hand turn, Push this switch while applying the front
on. push this switch to “6”. When released, or rear brake to crank the engine with
the starter. 9
the switch returns to the center position. ECA10050
To cancel the turn signal lights, push the cC
switch in after it has returned to the cen-
ter position. See page 5-1 for starting instructions
EAU12500 prior to starting the engine.
Horn switch “* *”
Press this switch to sound the horn.
3-2

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 INSTRUMENT AND CONTROL FUNCTIONS
EAU11620 EAU12150 EAU12900

Speedometer unit Fuel gauge Front brake lever

1 40
1 1 1
30 50
60
80
40 60
20 100

2
20

10
120 70
0

0 80
MPH

4 ZAUM00** ZAUM00** ZAUM00**

1. Speedometer 1. Fuel gauge 1. Front brake lever

5
The speedometer unit is equipped with The fuel gauge indicates the amount of The front brake lever is located on the
6 a speedometer and an odometer. The fuel in the fuel tank. The needle moves right handlebar grip. To apply the front
speedometer shows riding speed. The towards “E” (Empty) as the fuel level brake, pull this lever toward the handle-
odometer shows the total distance trav- decreases. When the needle reaches the bar grip.
7 eled. red line, refuel as soon as possible.
NOTE:
8 Do not allow the fuel tank to empty it-
self completely.
9

3-3

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 INSTRUMENT AND CONTROL FUNCTIONS
EAU12950 EAU32430 EAU32481

Rear brake lever Recommended fuel: Fuel tank cap

1 LINE ONLY
ZAUM00**
1. Rear brake lever
The rear brake lever is located on the
left handlebar grip. To apply the rear
brake, pull this lever toward the handle-
bar grip.
REGULAR UNLEADED GASO-
1
Fuel tank capacity: 2
4.5 L (1.18 US gal) (0.98 Imp.gal) 1
2
Your Yamaha engine has been designed
to use regular unleaded gasoline with a 3
pump octane number [(R+M)/2] of 86 or
higher, or a research octane number of 4
ZAUM00**
91 or higher. If knocking (or pinging) oc-
curs, use a gasoline of a different brand 1. Fuel tank cap cover
or a gasoline or premium unleaded fuel. 2. Match mark
5
Use of unleaded fuel will extend spark
To remove the fuel tank cap
plug life and reduce maintenance cost. 6
Slide the lock cover open, insert the key
into the lock, and then turn it 1/4 turn
Gasohol 7
clockwise. The lock will be released and
There are two types of gasohol: gaso-
the fuel tank cap can be removed.
hol containing ethanol and that contain-
ing methanol. Gasohol containing etha- 8
To install the fuel tank cap
nol can be used if ethanol content does
1. Insert the fuel tank cap into the tank
not exceed 10%. Gasohol containing 9
opening with the key inserted in the
methanol is not recommended by
lock and with the marks on the cap
Yamaha because it can cause damage
and tank aligned.
to the fuel system or vehicle perfor-
2. Turn the key counterclockwise to
mance problems.
the original position, remove it, and
then close the lock cover.

3-4

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 INSTRUMENT AND CONTROL FUNCTIONS
EWA10880 EAU13440
NOTE:
w Catalytic converter
The fuel tank cap cannot be installed
8 Do not overfill the fuel tank, oth- This vehicle is equipped with a catalytic
unless the key is in the lock. In addi-
erwise it may overflow when the converter in the muffler.
1 tion, the key cannot be removed if the EWA10860
fuel warms up and expands.
cap is not properly installed and locked.
8 Avoid spilling fuel on the hot
w
2 engine. The exhaust system is hot after op-
EWA10130
eration. Make sure that the exhaust
w system has cooled down before do-
ECA10070
3 Make sure that the fuel tank cap is
cC ing any maintenance work.
properly installed before riding.
Immediately wipe off spilled fuel with
4 ECA10700
a clean, dry, soft cloth, since fuel may
EAU13210
deteriorate painted surfaces or plas-
cC
Fuel The following precautions must be
5 tic parts.
observed to prevent a fire hazard or
6 1 other damages.
8 Use only unleaded gasoline. The
use of leaded gasoline will cause
7 unrepairable damage to the cata-
lytic converter.
8 8 Never park the vehicle near pos-
sible fire hazards such as grass
9 ZAUM00**
or other materials that easily
burn.
1. Fuel tank filler tube 8 Do not allow the engine to idle
too long.
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.

3-5

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 INSTRUMENT AND CONTROL FUNCTIONS
EAU13680 EAU13931

Kickstarter Seat NOTE:

Make sure that the seat is properly se-
cured before riding.
1
OPEN EAU14300

Helmet holder 2

1 3
1
ZAUM00** ZAUM00**
4

1. Kickstarter To open the seat 5

To star t the engine, fold out the 1. Place the scooter on the
kickstarter lever, move it down lightly centerstand.
2. Insert the key into the main switch, ZAUM00** 6
with your foot until the gears engage,
and then push it down smoothly but and then turn it counterclockwise.
1. Helmet holder (x2)
forcefully. NOTE: 7
Do not push inward when turning the key. The helmet holder is located under the
seat. 8
3. Fold the seat up. To secure a helmet to the helmet
holder 9
To close the seat 1. Open the seat. (See page 3-6.)
1. Fold the seat down, and then push 2. Attach the helmet to the helmet
it down to lock it in place. holder, and then securely close the
2. Remove the key from the main seat.
switch if the scooter will be left un-
attended.
3-6

5YR-F8199-10ch3.pmd 6 2003/10/27, 19:32

 INSTRUMENT AND CONTROL FUNCTIONS
EWA10160 EAU14510 ECA10080

w Storage compartment cC
Never ride with a helmet attached to Keep the following points in mind
the helmet holder, since the helmet 1 when using the storage compart-
1 may hit objects, causing loss of con- ment.
trol and possibly an accident. 8 Since the storage compartment
2 accumulates heat when exposed
To release the helmet from the hel- to the sun, do not store anything
3 met holder susceptible to heat inside it.
8 To avoid humidity from spread-
Open the seat, remove the helmet from ing through the storage compart-
4 ZAUM00**

the helmet holder, and then close the ment, wrap wet articles in a plas-
seat. 1. Storage compartment tic bag before storing them in the
5 compartment.
There is a storage compartment under 8 Since the storage compartment
6 the seat. (See page 3-6.) may get wet while the scooter is
EWA10960
being washed, wrap any articles
w
stored in the compartment in a
7 8 Do not exceed the load limit of 5
plastic bag.
kg (11 lb) for the storage com- 8 Do not keep anything valuable or
8 partment.
breakable in the storage com-
8 Do not exceed the maximum
partment.
load of 144 kg (317 lb) for the ve-
9
hicle.
To store a helmet in the storage com-
partment, place the helmet upside-down
with the front facing forward.

3-7

5YR-F8199-10ch3.pmd 7 2003/10/27, 19:32

 INSTRUMENT AND CONTROL FUNCTIONS
EAU15110 EAU15300
NOTE: Carrier Sidestand
8 Some helmets cannot be stored in
The sidestand is located on the left side
the storage compartment because
of the frame. Raise the sidestand or
of their size or shape. 1 1
lower it with your foot while holding the
8 Do not leave your scooter unat-
motorcycle upright.
tended with the seat open.
2
EAUT1070 NOTE:
Luggage hook The built-in sidestand switch is part of 3
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
ZAUM00**
4
(See further down for an explanation of
1 1. rear carrier the ignition circuit cut-off system.)
EWA10170 5
w EWA10240

8 Do not exceed the load limit of 3 w 6

kg (7 lb) for the carrier. The vehicle must not be ridden with
8 Do not exceed the maximum the sidestand down, or if the 7
ZAUM00**
load of 144 kg (317 lb) for the ve- sidestand cannot be properly moved
hicle. up (or does not stay up), otherwise
1. Luggage hook 8
EWAT1030 the sidestand could contact the
w ground and distract the operator, re-
8 Do not exceed the load limit of 3 sulting in a possible loss of control. 9
kg (7 lb) for the luggage hook. Yamaha’s ignition circuit cut-off sys-
8 Do not exceed the maximum tem has been designed to assist the
load of 144 kg (317 lb) for the ve- operator in fulfilling the responsibil-
hicle. ity of raising the sidestand before
starting off. Therefore, check this sys-

3-8

5YR-F8199-10ch3.pmd 8 2003/10/27, 19:32

 INSTRUMENT AND CONTROL FUNCTIONS
EAU15371
tem regularly as described below and
have a Yamaha dealer repair it if it Ignition circuit cut-off system
does not function properly. The ignition circuit cut-off system (com-
prising the sidestand switch and brake
1 light switches) has the following func-
tions.
2 8 It prevents star ting when the
sidestand is up, but neither brake
3 is applied.
8 It prevents starting when either
brake is applied, but the sidestand
4 is still down.
8 It cuts the running engine when the
5 sidestand is moved down.
Periodically check the operation of the
6 ignition circuit cut-off system according
to the following procedure.
EWA10250

7 w
If a malfunction is noted, have a
8 Yamaha dealer check the system be-
fore riding.
9

3-9

5YR-F8199-10ch3.pmd 9 2003/10/27, 19:32

 INSTRUMENT AND CONTROL FUNCTIONS

With the engine turned off: NOTE:

1. Move the sidestand down. This check is most reliable if performed with a warmed-
up engine. 1
2. Make sure that the engine stop switch is turned on.
3. Turn the key on.
4. Keep the front or rear brake applied. 2
5. Push the start switch.
Does the engine start? 3
The sidestand switch may be defective.
NO YES The scooter should not be ridden until checked by a
4
Yamaha dealer.
With the engine still off:
6. Move the sidestand up. 5
7. Keep the front or rear brake applied.
8. Push the start switch. 6
Does the engine start?
The brake switch may be defective.
YES NO 7
The scooter should not be ridden until checked by a
Yamaha dealer.
With the engine still running: 8
9. Move the sidestand down.
Does the engine stall? 9
The sidestand switch may be defective.
YES NO The scooter should not be ridden until checked by a
Yamaha dealer.
The system is OK. The scooter can be ridden.

3-10

5YR-F8199-10ch3.pmd 10 2003/10/27, 19:32

 PRE-OPERATION CHECKS
EAU15591
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
1 tion, to check the following points before each ride.
NOTE:
2 Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short
time; and the added safety it assures is more than worth the time involved.
3
EWA11150

w
4
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the vehicle.
5

4-1

5YR-F8199-10ch4.pmd 1 2003/10/27, 19:32

 PRE-OPERATION CHECKS
EAU15602

Pre-operation check list

ITEM CHECKS PAGE
• Check fuel level in fuel tank. 1
Fuel • Refuel if necessary. 3-2, 3-5
• Check fuel line for leakage.
• Check oil level in engine.
2
Engine oil • If necessary, add recommended oil to specified level. 6-24
• Check vehicle for oil leakage.
3
Final transmission oil • Check vehicle for oil leakage. 6-17
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system. 4
• Check fluid level in reservoir.
Front brake 6-12~6-13, 6-21
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage. 5
• Check the brake pads for wear.
• Check operation.
Rear brake
• Lubricate cable if necessary.
6-21
6
• Check lever free play.
• Adjust if necessary.
• Make sure that operation is smooth. 7
• Check cable free play.
Throttle grip 6-19
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing. 8
• Check for damage.
• Check tire condition and tread depth.
Wheels and tires
• Check air pressure.
6-19 9
• Correct if necessary.
• Make sure that operation is smooth.
Brake levers 6-14
• Lubricate lever pivoting points if necessary.
• Make sure that operation is smooth.
Centerstand, sidestand 6-15
• Lubricate pivots if necessary.

4-2

5YR-F8199-10ch4.pmd 2 2003/10/27, 19:32

 PRE-OPERATION CHECKS
ITEM CHECKS PAGE
• Make sure that all nuts, bolts and screws are properly tightened.
Chassis fasteners -
• Tighten if necessary.
Instruments, lights, signals • Check operation.
1 3-2~3-3
and switches • Correct if necessary.
Engine stop switch • Check operation. 3-2
2 • Check operation of ignition circuit cut-off system.
Sidestand switch 3-8~3-10
• If system is defective, have Yamaha dealer check vehicle.

4-3

5YR-F8199-10ch4.pmd 3 2003/10/27, 19:32


EAU15980
EWA10870
w down.
8 Become thoroughly familiar with
all operating controls and their
functions before riding. Consult
a Yamaha dealer regarding any
control or function that you do
not thoroughly understand.
8 Never start the engine or operate
it in a closed area for any length
of time. Exhaust fumes are poi-
sonous, and inhaling them can
cause loss of consciousness and
death within a short time. Always
make sure that there is adequate
ventilation.
8 For safety, always start the engine
with the centerstand down.
5YR-F8199-10ch5.pmd 1 2003/10/27, 19:33
OPERATION AND IMPORTANT RIDING POINTS
EAU16590
Starting a cold engine
ZAUM00**
ECA10250
cC
See page 5-3 for engine break-in in-
structions prior to operating the ve-
hicle for the first time.
In order for the ignition circuit cut-off
system to enable starting, the sidestand
must be up.
EWA10290
w 9
8 Before starting the engine, check
the function of the ignition cir-
cuit cut-off system according to
the procedure described on page
3-8.
5-1
8 Never ride with the sidestand
1. Turn the key to “ON” and make sure 1
that the engine stop switch is set
to “#”.
2
2. Close the throttle completely.
3. Start the engine by pushing the
start switch while applying the front 3
or rear brake.
4
NOTE:
If the engine does not start, release the 5
start switch, wait a few seconds, and
then try again. Each starting attempt
6
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one 7
attempt. If the engine does not start, try
with the throttle open 1/8 turn. 8
ECA11130
cC
For maximum engine life, always
warm the engine up before starting
off. Never accelerate hard when the
engine is cold!
 OPERATION AND IMPORTANT RIDING POINTS
EAU16770 EAU16780

Starting off Acceleration and deceleration

a 40
1 30
60
50

b
80
40 60
20 100

b 20
120 70
10
2 0
MPH
0

80

1
3 a
ZAUM00**

4 1. Start switch “,” ZAUM00** ZAUM00**

5 NOTE: The speed can be adjusted by opening

Before starting off, allow the engine to and closing the throttle. To increase the
warm up. speed, turn the throttle grip in direction
6 a. To reduce the speed, turn the throttle
grip in direction b.
1. While pulling the rear brake lever
7
with your left hand and holding the
carrier with your right hand, push
8 2 the scooter off the centerstand.
ZAUM00**
2. Sit astride the seat, and then ad-
9 just the rear view mirrors.
2. Kickstarter
3. Switch the turn signal on.
4. Check for oncoming traffic, and
then slowly turn the throttle grip (on
the right) in order to take off.
5. Switch the turn signal off.

5-2

5YR-F8199-10ch5.pmd 2 2003/10/27, 19:33

 OPERATION AND IMPORTANT RIDING POINTS
EAU16791
when wet. Therefore, slow down
Braking when approaching such areas
and cross them with caution.
8 Keep in mind that braking on a
1 2 wet road is much more difficult.
8 Ride slowly down a hill, as brak-
ing downhill can be very difficult.
EAU16830
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1000 km (600 mi). For 1
this reason, you should read the follow-
ing material carefully. 2

Since the engine is brand new, do not 3

put an excessive load on it for the first
1000 km (600 mi). The various parts in
ZAUM00**
the engine wear and polish themselves 4
to the correct operating clearances. Dur-
1. Rear
2. Front
ing this period, prolonged full-throttle 5
operation or any condition that might
1. Close the throttle completely. result in engine overheating must be 6
2. Apply both front and rear brakes si- avoided.
multaneously while gradually in- 7
creasing the pressure.
EWA10300

w 8
8 Avoid braking hard or suddenly
(especially when leaning over to 9
one side), otherwise the scooter
may skid or overturn.
8 Railroad crossings, streetcar
rails, iron plates on road con-
struction sites, and manhole cov-
ers become extremely slippery
5-3

5YR-F8199-10ch5.pmd 3 2003/10/27, 19:33

 OPERATION AND IMPORTANT RIDING POINTS
EAU16990 EAU17211 EWA10310
0~500 km (0~300 mi) Parking w
Avoid prolonged operation above 1/3 8 Since the engine and exhaust
throttle. system can become very hot,
1 park in a place where pedestri-
500~1000 km (300~600 mi) ans or children are not likely to
2 Avoid prolonged operation above 1/2 touch them.
throttle. 8 Do not park on a slope or on soft
ECA11500
ground, otherwise the vehicle
3 cC
may overturn.
After 1000 km (600 mi) of operation,
4 the engine oil must be changed, and ECA10380
the oil filter element and the oil cC
5 strainer cleaned.
Never park in an area where there are
fire hazards such as grass or other
1000 km (600 mi) and beyond flammable materials.
6
The vehicle can now be operated nor-
mally.
7 ECA10270

cC
8 If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
9
check the vehicle.
When parking, stop the engine, and then
remove the key from the main switch.

5-4

5YR-F8199-10ch5.pmd 4 2003/10/27, 19:33

 EAU17222
EAU17231
Safety is an obligation of the owner.
Periodic inspection, adjustment and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of mo-
torcycle inspection, adjustment, and lu-
brication are explained on the following
pages.
Maintenance, replacement, or repair
of the emission control devices and
systems may be performed by any
repair establishment or individual that
is certified (if applicable).
EWA10320
w 6
If you are not familiar with mainte-
nance work, have a Yamaha dealer do
it for you.
EAU17300
PERIODIC MAINTENANCE
PROPER PERIODIC MAINTENANCE
OF YOUR MOTORCYCLE IS IMPOR-
TANT IN ORDER TO ENJOY LONG,
PLEASURABLE SERVICE. ESPE-
CIALLY IMPORTANT ARE THE MAIN-
TENANCE SERVICES RELATED TO
EMISSIONS CONTROL. THESE CON-
TROLS NOT ONLY FUNCTION TO EN-
5YR-F8199-10ch6.pmd 1 2003/10/30, 11:59
PERIODIC MAINTENANCE AND MINOR REPAIR
SURE CLEANER AIR, BUT ARE ALSO
VITAL TO PROPER ENGINE OPERA-
TION AND MAXIMUM PERFOR-
MANCE. IN THE FOLLOWING PERI-
ODIC MAINTENANCE CHARTS, THE
SERVICES RELATED TO EMISSIONS
CONTROL ARE GROUPED SEPA-
RATELY. THESE SERVICES REQUIRE
SPECIALIZED DATA, KNOWLEDGE,
AND EQUIPMENT.YAMAHA DEALERS
ARE TRAINED AND EQUIPPED TO
PERFORM THESE PARTICULAR SER-
VICES.
EAU17370
Owner’s tool kit
1 Modifications not approved by
ZAUM00**
1. Owner’s tool kit
6-1
The owner’s tool kit is located under the
seat. (See page 3-6.)
The service information included in this
manual and the tools provided in the 1
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How- 2
ever, additional tools such as a torque
wrench may be necessary to perform 3
certain maintenance work correctly.
4
NOTE:
If you do not have the tools or experi-
5
ence required for a particular job, have
a Yamaha dealer perform it for you.
EWA10340
w 7
Yamaha may cause loss of perfor- 8
mance, excessive emissions, and ren-
der the vehicle unsafe for use. Con-
sult a Yamaha dealer before attempt- 9
ing any changes.
 PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17560*

Periodic maintenance chart for the emission control system

ODOMETER READING
1 600 mi 2,000 mi 4,000 mi 6,000 mi 8,000 mi
(1,000 (4,000 (7,000 (10,000 (13,000
NO. ITEM ROUTINE km) km) km) km) km)
or or or or or
2 1 6 12 18 24
month months months months months
3 1 * Fuel line • Check fuel hoses and vacuum hose for cracks or damage. — — — —
• Check valve clearance.
2 * Valves — — — —
• Adjust if necessary.
4 • Check condition.
— — — —
3 * Spark plug • Clean and regap.
5 • Replace. — —
• Clean. — —
4 * Air filter element
• Replace. — —
6
Crankcase breather • Check breather hose for cracks or damage.
5 * — — — —
system • Replace if necessary.
7 6 * Carburetor • Adjust engine idling speed. — — — — —
• Check for leakage.
7 * Exhaust system • Tighten if necessary. — — — —
8 • Replace gaskets if necessary.
Evaporative emission • Checkcontrol system for damage.
8 * — —
control system • Replace if necessary.
9
• Check the air cut-off valve, reed valve, and hose for damage.
9 * Air induction system — — — —
• Replace any damaged.

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
NOTE:
From 10000 mi (16000 km) or 30 months, repeat the maintenance intervals starting from 2000 mi (4000 km) or 6 months.
6-2

5YR-F8199-10ch6.pmd 2 2003/10/27, 19:33

 PERIODIC MAINTENANCE AND MINOR REPAIR
EAU32121

General maintenance and lubrication chart

ODOMETER READING
600 mi 2,000 mi 4,000 mi 6,000 mi 8,000 mi 1
(1,000 (4,000 (7,000 (10,000 (13,000
NO. ITEM ROUTINE km) km) km) km) km)
or or or or or
1 6 12 18 24
2
month months months months months
V-belt case air filter • Clean. — — 3
1 * elements • Replace. — —
• Check operation, fluid level and vehicle for fluid leakage.
— — — — — 4
2 * Front brake (See NOTE on page 6-5.)
• Replace brake pads. Whenever worn to the limit
• Check operation and adjust brake lever free play. — — — — — 5
3 * Rear brake
• Replace brake shoes. Whenever worn to the limit
• Check for cracks or damage. — — — —
4 * Brake hose 6
• Replace. (See NOTE on page 6-5.) Every 4 years
5 * Wheels • Check runout and for damage. — — — —
• Check tread depth and for damage.
7
• Replace if necessary.
6 * Tires — — — —
• Check air pressure.
• Correct if necessary. 8
7 * Wheel bearings • Check bearing for looseness or damage. — — — —
• Check bearing play and steering for roughness. — — — — — 9
8 * Steering bearings
• Lubricate with lithium-soap-based grease. Every 16,000 mi (24,000 km)
9 * Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. — — — —
• Check operation.
10 Sidestand, centerstand — — — —
• Lubricate.

6-3

5YR-F8199-10ch6.pmd 3 2003/11/11, 10:44

 PERIODIC MAINTENANCE AND MINOR REPAIR
ODOMETER READING
600 mi 2,000 mi 4,000 mi 6,000 mi 8,000 mi
(1,000 (4,000 (7,000 (10,000 (13,000
NO. ITEM ROUTINE km) km) km) km) km)
1 or or or or or
1 6 12 18 24
month months months months months
2 11 Sidestand switch • Check operation. — — — — —
*
12 * Front fork • Check operation and for oil leakage. — — — —
3 13 Shock absorber assembly • Check operation and shock absorber for oil leakage. — — — —
*
• Change.
14 Engine oil — Every 1,900 mi (3,000 km)
4 • Check oil level and vehicle for leakage.
15 * Engine oil filter element • Clean. — — —

5 16 * Engine oil strainer • Clean. — — —

17 Final transmission oil • Change. — — —

6 18 * V-belt • Replace. Every 12,000 mi (18,000 km)

Front and rear brake
19 * • Check operation. — — — — —
switches
7 20 Moving parts and cables • Lubricate. — — — —
• Check operation and free play.
Throttle grip housing and
8 21 * • Adjust the throttle cable free play if necessary. — — — —
cable
• Lubricate the throttle grip housing and cable.
Lights, signals and • Check operation.
22 * — — — — —
9 switches • Adjust headlight beam.

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
NOTE:
From 12000 mi (18000 km) or 36 months, repeat the maintenance intervals starting from 4000 mi (7000 km) or 12 months.

6-4

5YR-F8199-10ch6.pmd 4 2003/11/11, 10:44

 PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17620

NOTE:
8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8 Hydraulic brake system
9 When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid 1
level regularly and fill as required.
9 Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years. 2
9 Replace the brake hoses every four years or if cracked or damaged.
3

6-5

5YR-F8199-10ch6.pmd 5 2003/10/27, 19:33

 PERIODIC MAINTENANCE AND MINOR REPAIR
EAU18771 EAU19210 EAU19210

Removing and installing pan- Panel A Panel B

els
2
1
2
1
2

3
1 1
4 ZAUM00** ZAUM00**

2
ZAUM00**
1. Panel A 1. Panel B
5 2. Screw (x2) 2. Screw (x2)
1. Panel A
2. Panel B To remove the panel To remove the panel
6 Remove the screws, and then take the Remove the screws, and then take the
The panels shown above need to be re-
moved to perform some of the mainte- panel off. panel off.
7 nance jobs described in this chapter.
Refer to this section each time a panel To install the panel To install the panel
needs to be removed and installed. Place the panel in the original position, Place the panel in the original position,
8
and then install the screws. and then install the screws.

6-6

5YR-F8199-10ch6.pmd 6 2003/10/27, 19:33

 PERIODIC MAINTENANCE AND MINOR REPAIR
EAUT1170
To check the spark plug
Checking the spark plug 1. Check that the porcelain insulator
around the center electrode of the
1 spark plug is a medium-to-light tan 1
(the ideal color when the vehicle is
ridden normally).
2
NOTE: 1
If the spark plug shows a distinctly dif- 3
ZAUM0037
ferent color, the engine could be defec-
ZAUM00**
tive. Do not attempt to diagnose such 1. Spark plug gap 4
problems yourself. Instead, have a
1. Spark plug cap Yamaha dealer check the vehicle. Spark plug gap:
0.7~0.8 mm (0.028~0.032 in) 5
The spark plug is an important engine
component, which is easy to check. 2. Check the spark plug for electrode
2. Clean the surface of the spark plug 6
Since heat and deposits will cause any erosion and excessive carbon or
gasket and its mating surface, and
spark plug to slowly erode, the spark other deposits, and replace it if nec-
then wipe off any grime from the 7
plug should be removed and checked in essary.
spark plug threads.
accordance with the periodic mainte- 3. Install the spark plug with the spark
nance and lubrication chart. In addition, Specified spark plug: 8
plug wrench, and then tighten it to
the condition of the spark plug can re- CR7E (NGK)
the specified torque.
veal the condition of the engine. 9
To install the spark plug
Tightening torque:
To remove the spark plug 1. Measure the spark plug gap with a
Spark plug:
1. Remove panel A. (See page 6-6.) wire thickness gauge and, if nec-
13 Nm (1.3m • kgf, 9.4ft • lbf)
2. Remove the spark plug cap. essary, adjust the gap to specifi-
3. Remove the spark plug as shown, cation.
with the spark plug wrench included
in the owner’s tool kit.
6-7

5YR-F8199-10ch6.pmd 7 2003/10/27, 19:33

 PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
1 of the correct torque is 1/4~1/2 turn past
finger tight. However, the spark plug
should be tightened to the specified
2
torque as soon as possible.
3 filter elements more frequently if you are
4. Install the spark plug cap.
5. Install the panel.
EAUT1301
Air filter and V-belt case air fil-
ter elements
Air filter and V-belt case air filter
The air filter and V-belt case air filter el-
ements should be cleaned at the inter-
vals specified in the periodic mainte-
nance and lubrication chart. Clean both
1
riding in unusually wet or dusty areas. ZAUM00**

4 1. Air filter element

Cleaning the air filter element
1. Place the scooter on the 3. Pull the air filter element out, and
5
centerstand. then blow the dirt out with com-
pressed air as shown.
6 4. Check the air filter element for dam-
age and replace it if necessary.
7 5. Insert the air filter element into the
air filter case.
8
1
9
ZAUM00**

1. Air filter case cover

2. Remove the air filter case cover by

removing the screw.

6-8

5YR-F8199-10ch6.pmd 8 2003/10/27, 19:33

 PERIODIC MAINTENANCE AND MINOR REPAIR
Cleaning the V-belt case air filter ele-
ment
1. Remove the kickstarter lever by re-
moving the bolt. 1
1
2. Remove the crankcase cover by re-
moving the screws.
2 2

1 3
ZAUM00** ZAUM00**

1. Compressed air 1. Filter element holder 4

ECA10480 2. Filter element
cC 1 EWA10430

8 Make sure that the air filter ele-
ment is properly seated in the air
filter case.
8 The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
6.Install the air filter case cover by in-
stalling the screw.
w 5
3 2 Use only a dedicated parts cleaning
ZAUM00**
solvent. To avoid the risk of fire or 6
explosion, do not use gasoline or
1. Kickstarter
2. Bolt solvents with a low flash point. 7
3. Crankcase cover
ECA10520
8
3. Remove the filter element holder by cC
removing the screw. To avoid damaging the air filter ele-
4. Pull the air filter element out, and ment, handle it gently and carefully, 9
then clean it with solvent. After
and do not twist it.
cleaning, remove the remaining
solvent by squeezing the element.
5. Apply oil of the recommended type
to the entire surface of the sponge
material, and then squeeze the ex-
cess oil out.
6-9

5YR-F8199-10ch6.pmd 9 2003/10/27, 19:33

 PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
The air filter element should be wet but
not dripping.
1

2 Recommended oil:
Engine oil
3
6. Insert the element into the air filter
case.
4 7. Install the filter element holder by
installing the screw.
5 8. Install the crankcase cover by in-
stalling the screws.
9. Install the kickstarter lever by in-
6
stalling the bolt, then tightening the
bolt to the specified torque.
7
Tightening torque:
8 Kickstarter bolt:
23 Nm (2.3m • kgf, 16.6ft • lbf)
9

6-10

5YR-F8199-10ch6.pmd 10 2003/10/27, 19:33

 PERIODIC MAINTENANCE AND MINOR REPAIR
EAU24131 EAU24201
1. Remove the turn signal light lens
Replacing the tail/brake light Replacing a turn signal light by removing the screw.
bulb bulb 2. Remove the defective bulb by push-
ing it in and turning it counterclock- 1
wise.
2 3. Insert a new bulb into the socket,
1
2 push it in, and then turn it clock- 2

1 wise until it stops.

4. Install the lens by installing the 3
screw.
ECA11190

cC 4
ZAUM00** ZAUM00**
Do not overtighten the screw, other-
wise the lens may break. 5
1. Light lens 1. Front light lens
2. Bulb 2. Bulb
6
1. Remove the tail/brake light lens by
removing the screws. 2
2. Remove the defective bulb by push- 7
ing it in and turning it counterclock-
wise. 8
3. Insert a new bulb into the socket,
1
push it in, and then turn it clock- 9
wise until it stops.
4. Install the lens by installing the ZAUM00**

screws.
ECA10680
1. Rear light lens
cC 2. Bulb
Do not overtighten the screws, other-
wise the lens may break.
6-11

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 PERIODIC MAINTENANCE AND MINOR REPAIR
EAU22380 EAU22410 EAU22540

Checking the front brake pads Front brake pads Rear brake shoes
and rear brake shoes
The front brake pads and the rear brake
1 3 1
shoes must be checked for wear at the
intervals specified in the periodic main-
2 tenance and lubrication chart.

3 2
1
4 ZAUM00** ZAUM00**
2

1. Wear indicator 1. Wear indicator

5 2. Brake disk
3. Brake pads
6 Each front brake pad is provided with a
wear indicator, which allows you to
7 check the brake pad wear without hav-
ing to disassemble the brake. To check
the brake pad wear, check the position
8 of the wear indicator while applying the
brake. If a brake pad has worn to the
9 point that the wear indicator almost
touches the brake disc, have a Yamaha
dealer replace the brake pads as a set.
2. Wear limit line
The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to dis-
assemble 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 dealer replace
the brake shoes as a set.

6-12

5YR-F8199-10ch6.pmd 12 2003/10/27, 19:33


EAU32341
Observe these precautions:
Checking the brake fluid level
1 ter cylinder is level by turning the
LOWER MIN
ZAUM00**
1. Minimum level mark
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing 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
fluid level is low, be sure to check the
brake pads for wear and the brake sys-
tem for leakage.
5YR-F8199-10ch6.pmd 13
PERIODIC MAINTENANCE AND MINOR REPAIR
8 When checking the fluid level,
make sure that the top of the mas-
handlebars.
Use only the recommended qual-
ity brake fluid, otherwise the rub-
ber seals may deteriorate, causing
leakage and poor braking perfor-
mance.
Recommended brake fluid:
DOT 4
8 Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and lead
to poor braking performance.
8 Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower the
boiling point of the fluid and may
result in vapor lock.
8 Brake fluid may deteriorate painted
surfaces or plastic parts. Always
clean up spilled fluid immediately.
8 As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
6-13
2003/10/27, 19:33
brake fluid level goes down sud-
denly, have a Yamaha dealer check
the cause.
EAU22720
1
Changing the brake fluid
Have a Yamaha dealer change the brake
fluid at the intervals specified in the 2
NOTE after the periodic maintenance
and lubrication chart. In addition, have 3
the oil seals of the brake master cylin-
der and caliper as well as the brake hose
4
replaced at the intervals listed below or
whenever they are damaged or leaking.
8 Oil seals: Replace every two years. 5
8 Brake hose: Replace every four
years. 6
7
8
9
 PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23090
Checking and lubricating the
cables
The operation of all control cables and
1
the condition of the cables should be
checked before each ride, and the
2 cables and cable ends should be lubri-
cated if necessary. If a cable is dam-
3 aged or does not move smoothly, have
a Yamaha dealer check or replace it.
4
Recommended lubricant:
Yamaha Chain and Cable Lube or
5 engine oil SAE 10W-30 (API SE)
EWA10710
6
w intervals specified in the periodic main-
Damage to the outer housing of
7 cables may result in internal rusting
and cause interference with cable
8 movement. Replace damaged cables
as soon as possible to prevent un-
9 safe conditions.
5YR-F8199-10ch6.pmd 14
EAU23110 EAU23170
Checking and lubricating the Lubricating the front and rear
throttle grip and cable brake levers
The 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.
ZAUM00**
The pivoting points of the front and rear
brake levers must be lubricated at the
tenance and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
6-14
2003/10/27, 19:33
 PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23210 EAU23271
To check the operation
Checking and lubricating the 1. Place the motorcycle on a level sur-
Checking the front fork
centerstand and sidestand face and hold it in an upright posi-
tion. 1
2. While applying the front brake, push
down hard on the handlebars sev-
eral times to check if the front fork 2
compresses and rebounds
smoothly. 3
ECA10590

cC 4
ZAUM00**

ZAUM00**
The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-to-
metal contact surfaces should be lubri-
cated if necessary.
EWA10740
w w
If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or repair
it.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
If any damage is found or the front
The condition and operation of the front fork does not operate smoothly, have 5
fork must be checked as follows at the a Yamaha dealer check or repair it.
intervals specified in the periodic main- 6
tenance and lubrication chart.
7
To check the condition
EWA10750
8
Securely support the motorcycle so
that there is no danger of it falling
9
over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
6-15

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 PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23280 EAU23780
2. Hold the lower ends of the front fork
Checking the steering legs and try to move them forward Replacing the headlight bulb
and backward. If any free play can
be felt, have a Yamaha dealer check
1
or repair the steering. 1
2

4 ZAUM00** ZAUM00**

Worn or loose steering bearings may 1. Headlight unit

5
cause danger. Therefore, the operation This model is equipped with a quartz
of the steering must be checked as fol- bulb headlight. If the headlight bulb burns
6 lows at the intervals specified in the out, replace it as follows.
periodic maintenance and lubrication 1. Remove the headlight unit by re-
7 chart. moving the screws.
1. Place a stand under the engine to
8 raise the front wheel off the ground.
EWA10750

w
9 Securely support the motorcycle so
that there is no danger of it falling
over.

6-16

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 PERIODIC MAINTENANCE AND MINOR REPAIR
EWA10790 EAU20060

w Final transmission oil

1 Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
2 touch the bulb until it has cooled
down.
4. Place a new headlight bulb into po-
ZAUM00**
sition, and then secure it with the
bulb holder.
1. Headlight coupler ECA10660
2. Bulb cover
cC
2. Disconnect the headlight coupler, Do not touch the glass part of the
and then remove the bulb cover. headlight bulb to keep it free from oil,
otherwise the transparency of the
glass, the luminosity of the bulb, and
the bulb life will be adversely affected.
1 Thoroughly clean off any dirt and fin-
gerprints on the headlight bulb us-
ing a cloth moistened with alcohol
or thinner.
ZAUM00**
5. Install the headlight bulb cover, and
then connect the coupler.
1. Bulb holder 6. Install the headlight unit by install-
ing the screws.
3. Remove the headlight bulb holder
The final transmission case must be
checked for oil leakage before each ride.
If any leakage is found, have a Yamaha 1
dealer check and repair the scooter. In
addition, the final transmission oil must 2
be changed as follows at the intervals
specified in the periodic maintenance 3
and lubrication chart.
1. Start the engine, warm it up by
riding the scooter for several min- 4
utes, and then stop the engine.
2. Place the scooter on the 5
centerstand.
3. Place an oil pan under the final 6
transmission case to collect the
used oil.
7
1 8
9
ZAUM00**

7. Have a Yamaha dealer adjust the

by turning it counterclockwise, and
headlight beam if necessary. 1. Final transmission oil filler cap
then remove the defective bulb.
6-17

5YR-F8199-10ch6.pmd 17 2003/10/27, 19:33

 PERIODIC MAINTENANCE AND MINOR REPAIR
Recommended final transmission
oil:
See page 8-1.
1
1 Oil quantity:
0.13 L (0.14 US qt) (0.1 Imp.qt)
2 EWA11310

w
3 8 Make sure that no foreign mate-
ZAUM00**
rial enters the final transmission
4 case.
1. Final transmission gear oil drain bolt
8 Make sure that no oil gets on the
4. Remove the oil filler cap and drain tire or wheel.
5 bolt to drain the oil from the final
transmission case. 7. Check the final transmission case
6 5. Install the final transmission oil for oil leakage. If oil is leaking,
drain bolt, and then tighten it to the check for the cause.
specified torque.
7
Tightening torque:
8 Final transmission oil drain bolt:
23 Nm (2.3m • kgf, 16.6ft • lbf)
9
6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten the
oil filler cap.

6-18

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 PERIODIC MAINTENANCE AND MINOR REPAIR
EAU21250 EAU21860
of the tires equals the ambient
Adjusting the carburetor Tires temperature).
The carburetor is an important part of 8 The tire air pressure must be
the engine and its emission control sys- adjusted in accordance with the
1 1
tem, which requires very sophisticated riding speed and with the total
adjustment. Therefore, carburetor adjust- weight of rider, passenger, cargo,
ments should be left to Yamaha dealer, and accessories approved for this 2
who has the necessary professional model.
knowledge and experience. 2
3
EAU21380 Tire air pressure
(measured on cold tires)
Adjusting the throttle cable
Load* Front Rear 4
free play ZAUM0054

150 kPa 200 kPa

1. Tread depth Up to 90 kg (198 lb) 1.50 kgf/cm2 2.0 kgf/cm2
2. Side wall 22 psi 29 psi 5
150 kPa 225 kPa
To maximize the performance, durabil- 90 kg (198 lb)–
a maximum
1.50kgf/cm2 2.25 kgf/cm2
6
ity, and safe operation of your scooter, 22psi 32 psi
note the following points regarding the
Maximum load* 144 kg (317 lb) 7
specified tires.
* Total weight of rider, passenger, cargo and
accessories
Tire air pressure 8
ZAUM00**
The tire air pressure should be checked EWA10510
and, if necessary, adjusted before each w 9
a. 1.5 ~ 3.5mm ride.
EWA10500 Proper loading of your vehicle is im-
The throttle cable free play should mea- w portant for several characteristics of
sure 1.5~3.5 mm (0.06~0.14 in) at the 8 The tire air pressure must be your vehicle, such as handling, brak-
throttle grip. Periodically check the checked and adjusted on cold ing, performance and safety. Do not
throttle cable free play and, if necessary, tires (i.e., when the temperature carry loosely packed items that can
have a Yamaha dealer adjust it. shift. Securely pack your heaviest
6-19

5YR-F8199-10ch6.pmd 19 2003/10/27, 19:33

 PERIODIC MAINTENANCE AND MINOR REPAIR
EWA10580
items close to the center of the mo- NOTE:
torcycle, and distribute the weight w
The tire tread depth limits may differ from
evenly from side to side. Properly 8 It is dangerous to ride with a
country to country. Always comply with
adjust the suspension for your load, worn-out tire. When a tire tread
1 the local regulations.
and check the condition and pressure begins to show crosswise lines,
of your tires. NEVER OVERLOAD have a Yamaha dealer replace the
2 Tire information tire immediately.
YOUR VEHICLE. Make sure that the
This scooter is equipped with cast 8 The replacement of all wheel-
total weight of the cargo, rider, pas-
wheels and tubeless tires with valves. and brake-related parts, includ-
3 senger, and accessories (cowling,
saddlebags, etc. if approved for this EWA10590
ing the tires, should be left to a
model) does not exceed the maxi- w Yamaha dealer, who has the nec-
4 essary professional knowledge
mum load of the vehicle. Operation Operating the scooter with exces-
of an overloaded motorcycle could and experience.
5 sively worn tires decrease riding sta-
cause tire damage, an accident, or bility and can lead to loss of control.
even injury. Have excessively worn tires replaced
6 by a Yamaha dealer immediately.
Tire inspection Brakes, tires, and related wheel parts
7 The tires must be checked before each replacement should be left to a
ride. If a tire tread shows crosswise lines Yamaha Service Technician.
(minimum tread depth), if the tire has a
8
nail or glass fragments in it, or if the FRONT
sidewall is cracked, have a Yamaha Manufacturer Size Model
9 dealer replace the tire immediately. Cheng shin 3.50-10 51J

REAR
Minimum tire tread depth (front and
Manufacturer Size Model
rear):
Cheng shin 3.50-10 51J
0.8 mm (0.03 in)

6-20

5YR-F8199-10ch6.pmd 20 2003/10/27, 19:33

 PERIODIC MAINTENANCE AND MINOR REPAIR
EAU21960 EAU22100 EAU22170

Cast wheels Adjusting the brake lever free Adjusting the rear brake lever
To maximize the performance, durabil- play free play
ity, and safe operation of your motor-
cycle, note the following points regard- 1
ing the specified wheels. 1
8 The wheel rims should be checked 1 2
for cracks, bends or warpage be-
fore each ride. If any damage is 3
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the ZAUM0107
4
wheel. A deformed or cracked wheel ZAUM0108
1. Free play
must be replaced. 5
8 The wheel should be balanced The brake lever free play should mea- 1. Free play
whenever either the tire or wheel sure 2~5 mm (0.08~0.2 in) as shown.
6
has been changed or replaced. An Periodically check the brake lever free
unbalanced wheel can result in poor play and, if necessary, have a Yamaha
performance, adverse handling dealer adjust it. 7
EWA10640
characteristics, and a shortened
tire life.
w 1
8
8 Ride at moderate speeds after An incorrect brake lever free play in-
changing a tire since the tire sur- dicates a hazardous condition in the
brake system. Do not operate the
b 9
face must first be “broken in” for it
motorcycle until the brake system has ZAUM00** a
to develop its optimal characteris-
tics. been checked or repaired by a
1. Adjusting nut
Yamaha dealer.

6-21

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 PERIODIC MAINTENANCE AND MINOR REPAIR
EAUT1230 EWA10760
The brake lever free play should mea-
sure 10~20 mm (0.4~0.8 in) as shown. Battery w
Periodically check the brake lever free 8 Electrolyte is poisonous and dan-
play and, if necessary, adjust it as fol- gerous since it contains sulfuric
1 acid, which causes severe burns.
lows.
To increase the brake lever free play, Avoid any contact with skin, eyes
2 turn the adjusting nut at the brake shoe or clothing and always shield
plate in direction (a). To decrease the your eyes when working near
3 brake lever free play, turn the adjusting batteries. In case of contact, ad-
nut in direction (b). 1 minister the following FIRST AID.
EWA10650 9 EXTERNAL: Flush with
4 w ZAUM00**
plenty of water.
If proper adjustment cannot be ob- 9 INTERNAL: Drink large
1. Battery
5 tained as described, have a Yamaha quantities of water or milk
dealer make this adjustment. This model is equipped with a sealed- and immediately call a
6 type (MF) battery, which does not re- physician.
quire any maintenance. There is no need 9 EYES: Flush with water for
to check the electrolyte or to add dis- 15 minutes and seek prompt
7 tilled water. medical attention.
ECA10620
8 Batteries produce explosive hy-
8 cC drogen gas. Therefore, keep
Never attempt to remove the battery sparks, flames, cigarettes, etc.,
cell seals, as this would permanently away from the battery and pro-
9
damage the battery. vide sufficient ventilation when
charging it in an enclosed space.
8 KEEP THIS AND ALL BATTERIES
OUT OF THE REACH OF CHIL-
DREN.

6-22

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 PERIODIC MAINTENANCE AND MINOR REPAIR
ECA10630 EAUT1240
The battery is located under the
footboard. Remove panel B to access cC Replacing the fuse
the battery. (See page 6-6.) 8 Always keep the battery charged.
Storing a discharged battery can
1
To charge the battery cause permanent battery dam-
Have a Yamaha dealer charge the bat- age.
tery as soon as possible if it seems to 8 To charge a sealed-type (MF) bat- 1 2
have discharged. Keep in mind that the tery, a special (constant-voltage)
battery tends to discharge more quickly battery charger is required. Us- 3
if the vehicle is equipped with optional ing a conventional battery
electrical accessories. charger will damage the battery.
ZAUM00**
4
If you do not have access to a
To store the battery sealed-type (MF) battery charger, 1. Fuse
1. If the vehicle will not be used for have a Yamaha dealer charge 5
more than one month, remove the your battery. The fuse holder is located beside the
battery, fully charge it, and then battery. Remove panel B to access the 6
place it in a cool, dry place. fuse. (See page 6-6.)
2. If the battery will be stored for more 7
than two months, check it at least If the fuse is blown, replace it as fol-
once a month and fully charge it if lows.
necessary. 1. Turn the key to “OFF” and turn off 8
3. Fully charge the battery before in- all electrical circuits.
stallation. 2. Remove the blown fuse, and then 9
4. After installation, make sure that install a new fuse of the specified
the battery leads are properly con- amperage.
nected to the battery terminals.
Specified fuse:
10 A

6-23

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 PERIODIC MAINTENANCE AND MINOR REPAIR
ECA10640 EAUT1180

Engine oil and oil strainer NOTE:

cC Make sure that the vehicle is positioned
Do not use a fuse of a higher amper- straight up when checking the oil level.
age rating than recommended to A slight tilt to the side can result in a
1 2
avoid causing extensive damage to false reading.
the electrical system and possibly a
2 fire. 3
2. Start the engine, warm it up for sev-
eral minutes, and then turn it off.
3 3. Turn the key to “ON” and turn on 3. Wait a few minutes until the oil
the electrical circuits to check if the settles, and then check the oil level
devices operate.
1
4 ZAUM00** through the check window located
4. If the fuse immediately blows again, at the bottom-left side of the crank-
have a Yamaha dealer check the 1. Level check window case.
5 electrical system. 2. Maximum level
3. Minimum level
6 NOTE:
The engine oil level should be checked
The engine oil should be between the
before each ride. In addition, the oil must
minimum and maximum level marks.
7 be changed and the oil strainer cleaned
at the intervals specified in the periodic
maintenance and lubrication chart. 4. If the engine oil is below the mini-
8 mum level mark, add sufficient oil
To check the engine oil level of the recommended type to raise
9 1. Place the vehicle on the it to the correct level.
centerstand.

6-24

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 PERIODIC MAINTENANCE AND MINOR REPAIR
To change the engine oil and clean
the oil strainer

1 4 3 2 1
1

2
1
1 3
ZAUM00** ZAUM00**

1. Drain bolt A 1. Drain bolt B 4

ZAUM00**
ECA10410 2. O-ring
1. Oil filler cap
cC 3. Spring
5
4. Strainer
When removing the engine oil drain
1. Start the engine, warm it up for sev- 6.Check the O-ring for damage and re-
bolt, the O-ring, spring, and oil
eral minutes, and then turn it off. place it if necessary. 6
strainer will fall out. Take care not to
2. Place an oil pan under the engine 7. Install the oil strainer, spring, O-ring
lose these parts.
to collect the used oil. and engine oil drain bolts, and then 7
3. Remove panel A. (See page 6-6.) tighten the drain bolts to the speci-
4. Remove the engine oil filler cap and 5. Clean the oil strainer with solvent,
and then check it for damage and fied torque. 8
drain bolts to drain the oil from the
crankcase. replace it if necessary.
Tightening torque:
Engine oil drain bolt A: 9
23 Nm (2.3m • kgf, 16.6ft • lbf)
Engine oil drain bolt B:
32 Nm (3.2m • kgf, 23.1ft • lbf)

6-25

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 PERIODIC MAINTENANCE AND MINOR REPAIR
EAU25860
NOTE: 9. Start the engine, and then let it idle
for several minutes while checking Troubleshooting
Make sure that the O-ring is properly
it for oil leakage. If oil is leaking, Although Yamaha scooters receive a
seated.
immediately turn the engine off and thorough inspection before shipment
1 from the factory, trouble may occur dur-
check for the cause.
8. Add the specified amount of the ing operation. Any problem in the fuel,
10. Turn the engine off, and then check
2 recommended engine oil, and then compression, or ignition systems, for
the oil level and correct it if neces-
install and tighten the engine oil filler example, can cause poor starting and
sary.
cap. loss of power.
3 11. Install the panel.
The following troubleshooting chart rep-
Recommended engine oil: resents a quick and easy procedure for
4 See page 8-1. checking these vital systems yourself.
Oil change quantity: However, should your scooter require any
5 1.0 L (1.09 US qt) (0.92 Imp.qt) repair, take it to a Yamaha dealer, whose
skilled technicians have the necessary
ECA11670

6 tools, experience, and know-how to ser-

cC vice the scooter properly.
8 Do not use oils with a diesel Use only genuine Yamaha replacement
7 specification of “CD” or oils of a parts. Imitation parts may look like
higher quality than specified. In Yamaha parts, but they are often infe-
8 addition, do not use oils labeled rior, have a shorter service life and can
“ENERGY CONSERVING II” or lead to expensive repair bills.
higher.
9 8 Be sure no foreign material en-
ters the crankcase.

6-26

5YR-F8199-10ch6.pmd 26 2003/10/27, 19:33


Troubleshooting chart
w
Keep away open flames and do not smoke while checking or working on the fuel system.
1. Fuel
Check the fuel level in
the fuel tank.
2. Compression
Operate the electric starter.
3. Ignition
Remove the spark plug
and check the electrodes.
4. Battery
Operate the electric starter.
5YR-F8199-10ch6.pmd 27
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU25901
EWA10840
1
2
There is enough fuel. Check the compression.
3
The engine does not start.
There is no fuel. Supply fuel.
Check the compression.
4
There is compression. Check the ignition.
5
Have a Yamaha dealer
There is no compression.
check the vehicle. 6
Wipe off with a dry cloth and correct the Open the throttle halfway and operate 7
Wet
spark plug gap, or replace the spark plug. the electric starter.
The engine does not start. 8
Dry Have a Yamaha dealer check the vehicle.
Check the battery.
9
The engine turns over
The battery is good.
quickly. The engine does not start.
Have a Yamaha dealer
The engine turns over Check the battery lead connections, check the vehicle.
slowly. and charge the battery if necessary.
6-27
2003/10/27, 19:33
 SCOOTER CARE AND STORAGE
EAU26090
Care
While the open design of a scooter re-
veals the attractiveness of the technol-
1 ogy, it also makes it more vulnerable.
Rust and corrosion can develop even if
2 high-quality components are used. A
rusty exhaust pipe may go unnoticed on
3 a car, however, it detracts from the over-
all appearance of a scooter. Frequent and
proper care does not only comply with
4 the terms of the warranty, but it will also
keep your scooter looking good, extend
5 its life and optimize its performance.
6 Before cleaning
1. Cover the muffler outlet with a plas-
tic bag after the engine has cooled
7 down.
2. Make sure that all caps and cov-
8 ers as well as all electrical couplers
and connectors, including the spark
9 plug cap, are tightly installed.
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
degreaser off with water.
5YR-F8199-10ch7.pmd 1 2003/10/27, 19:34
Cleaning
ECA10780
cC
8 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 affected
area any longer than instructed.
Also, thoroughly rinse the area
off with water, immediately dry
it, and then apply a corrosion
protection spray.
8 Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge with
mild detergent and water to clean
plastic.
8 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 cleaning prod-
ucts, solvent or thinner, fuel
(gasoline), rust removers or in-
hibitors, brake fluid, antifreeze or
electrolyte.
8 Do not use high-pressure wash-
7-1
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and
swingarm bearings, fork and
brakes), electric components
(couplers, connectors, instru-
ments, switches and lights),
breather hoses and vents.
8 For scooters equipped with a
windshield: Do not use strong
cleaners or hard sponges as they
will cause dulling or scratching.
Some cleaning compounds for
plastic may leave scratches on
the windshield. Test the product
on a small hidden part of the
windshield to make sure that it
does not leave any marks. If the
windshield is scratched, use a
quality plastic polishing com-
pound after washing.
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 min-
utes before cleaning.
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on the
roads during winter are extremely corro-
sive 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 may
remain well into spring.
1. Clean the scooter with cold water
and a mild detergent after the en-
gine has cooled down.
ECA10790
cC
Do not use warm water since it in-
creases the corrosive action of the
salt.
5YR-F8199-10ch7.pmd 2 2003/10/27, 19:34
SCOOTER CARE AND STORAGE
EWA10940
2. Apply a corrosion protection spray
on all metal, including chrome- and w
nickel-plated, surfaces to prevent 8 Make sure that there is no oil or
corrosion. wax on the brakes or tires. If nec- 1
essary, clean the brake discs and
After cleaning brake linings with a regular brake
1. Dry the scooter with a chamois or 2
disc cleaner or acetone, and
an absorbing cloth. wash the tires with warm water
2. Use a chrome polish to shine and a mild detergent. 3
chrome, aluminum and stainless- 8 Before operating the scooter test
steel parts, including the exhaust its braking performance and cor- 4
system. (Even the thermally in- nering behavior.
duced discoloring of stainless-steel
exhaust systems can be removed 5
ECA10800
through polishing.)
3. To prevent corrosion, it is recom- cC 6
mended to apply a corrosion pro- 8 Apply spray oil and wax spar-
tection spray on all metal, includ- ingly and make sure to wipe off 7
ing chrome- and nickel-plated, sur- any excess.
faces. 8 Never apply oil or wax to any rub-
4. Use spray oil as a universal cleaner ber and plastic parts, but treat 8
to remove any remaining dirt. them with a suitable care prod-
uct. 9
5. Touch up minor paint damage 8 Avoid using abrasive polishing
caused by stones, etc. compounds as they will wear
6. Wax all painted surfaces. away the paint.
7. Let the scooter dry completely be-
fore storing or covering it.
7-2
 SCOOTER CARE AND STORAGE
EAU26300
NOTE:
Storage
Consult a Yamaha dealer for advice on
Short-term
what products to use.
Always store your scooter in a cool, dry
1 place and, if necessary, protect it
against dust with a porous cover.
ECA10820
2 4. Perform the following steps to pro-
cC
8 Storing the scooter in a poorly
3
ventilated room or covering it
with a tarp, while it is still wet,
4 will allow water and humidity to
seep in and cause rust.
5 8 To prevent corrosion, avoid
damp cellars, stables (because of
the presence of ammonia) and
6
areas where strong chemicals are
stored.
7
8 times with the starter. (This will
Long-term
Before storing your scooter for several
9 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
7-3
5YR-F8199-10ch7.pmd 3 2003/10/27, 19:34
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.
tect 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 spark-
ing during the next step.)
d. Turn the engine over several
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.
 SCOOTER CARE AND STORAGE
EWA10950
°F) or more than 30 °C (90 °F)]. For
w more information on storing the
To prevent damage or injury from battery, see page 6-23.
sparking, make sure to ground the
NOTE: 1
spark plug electrodes while turning
Make any necessary repairs before stor-
the engine over.
ing the scooter.
2
5. Lubricate all control cables and the
pivoting points of all levers and 3
pedals as well as of the sidestand/
centerstand. 4
6. Check and, if necessary, correct
the tire air pressure, and then lift
the scooter so that both of its 5
wheels are off the ground. Alterna-
tively, turn the wheels a little every 6
month in order to prevent the tires
from becoming degraded in one 7
spot.
7. Cover the muffler outlet with a plas-
tic bag to prevent moisture from en- 8
tering it.
8. Remove the battery and fully charge 9
it. Store it in a cool, dry place and
charge it once a month. Do not store
the battery in an excessively cold
or warm place [less than 0 °C (30

7-4

5YR-F8199-10ch7.pmd 4 2003/10/27, 19:34

 SPECIFICATIONS
Dimensions: Oil type or grade Fuel
Overall length: Engine oil Type
1,755 mm (69.1 in) Type Regular unleaded gasoline(91 or higher)
Overall width: Fuel tank capacity
-20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚
1 699 mm (27.5 in) 4.5 L (1.18 US qt, 0.98 lmp.gal)
Overall height: Carburetor
1,063 mm (41.8 in) Type×quantity
SAE 10W-30
2 Seat height: BS26×1
759 mm (29.8 in) SAE 10W-40 Manufacturer
Wheel base: Mikuni
SAE 20W-40
3 1,230 mm (48.4 in) Spark plug
Ground clearance: SAE 20W-50 Type / Manufacturer
95 mm (3.8 in) CR7E / NGK
4 Minimum turning radius:
ZAUM00**
Gap
1,800 mm (72 in) 0.7 ~ 0.8 mm (0.028 ~ 0.032 in)
Weight: Recommended engine oil classification Transmission
5 with oil and full fuel tank: API Service SE, SF type or higher Primary reduction system
109 kg (240 lb) Final gear oil Helical gear
Engine: Type Primary reduction ratio
6 Engine type SAE 85 W 140 40/15(2.666)
Air-cooled 4-stroke, SOHC Oil quantity Secondary reduction system
Cylinder arrangement: Engine oil Spur gear
7 Forward-inclined single cylinder Periodic oil change Secondary reduction ratio
Displacement: 1.0 L (1.09 US qt, 0.92 lmp.qt) 38/13(2.923)
125 cm3 Total amount Transmission type
8 Bore Stroke 1.2 L (1.31 US qt, 1.10 lmp.qt) Single speed automatic(V-belt type)
51.5×60.0 mm (2.0×2.4 in) Final gear case oil Operation
9 Compression ratio: Periodic oil change Centrifugal automatic type
9.8:1 0.13 L Chassis
Starting system: Total amount Frame type
Electric / kick starter 0.15 L Steel tube underbone
Lubrication system: Air filter Caster angle
Wet sump Paper type element 32°
Trail
75 mm

8-1

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 SPECIFICATIONS
Front tire Rear wheel Electrical system
Type Type Ignition system
Tubeless Cast C.D.I.
Size Size Charging system
3.50-10 51J J10×MT 2.5 Type 1
Manufacturer Front brake C.D.I. magneto generator
Cheng shin Type Standard output
Rear tire Single disc brake 14 V,120W / 5,000 r/min 2
Type Operation Battery
Tubeless Right hand operation Type
Size Fluid GTX 7A-BS 3
3.50-10 51J DOT 4 Voltage, capacity
Manufacturer Rear brake 12 V, 6 AH
Cheng shin Type Headlight type 4
Maximum load* Drum Bulb
144 kg (317 lb) Operation Bulb voltage, wattage quantity
Tire air pressure(Cold tire) Left hand operation Headlight
5
Up to 90 kg (198 lb) load* Front suspension 12 V, 60 / 65 W×1
Front Type Tail / brake light
150 kPa(1.50 kg / cm2, 22 psi)
6
Telescopic fork 12 V, 8 / 27 W×1
Rear Rear suspension Turn signal light
200 kPa(2.00 kg / cm2, 29 psi) Type 12 V, 10 W×4
90 kg load ~ maximum load*
7
Unit swing Meter light
Front Shock absorbers 14 V, 3 W×1
150 kPa(1.50 kg / cm2, 22 psi) Front Fuel meter light 8
Rear Coil spring / oil damper 14 V, 3 W×1
225 kPa(2.25 kg / cm2,32 psi) Rear High beam indicator light
*Load is total weight of cargo, rider and acces- Coil spring / oil damper 12 V, 3 W×1 9
sories. Turn indicator light
Wheel travel
Front wheel Front 12 V, 1.7 W×1
Type 59 mm Fuse
Cast Rear 10A 1
Size 54 mm
J10×MT 2.5

8-2

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 CONSUMER INFORMATION
EAU26351 EAU26390 EAU26410

Identification numbers Key identification number Vehicle identification number

Record the key identification number,
vehicle identification number and model
1 label information in the spaces provided
below for assistance when ordering
1
2 spare parts from a Yamaha dealer or for 1
reference in case the vehicle is stolen.
3
KEY IDENTIFICATION NUMBER:

4 ZAUM00** ZAUM00**

1. Key identification number 1. Vehicle identification number

5
VEHICLE IDENTIFICATION NUMBER: The key identification number is The vehicle identification number is
stamped into the key. stamped into the frame.
6 Record this number in the space pro- NOTE:
vided and use it for reference when or- The vehicle identification number is used
7 dering a new key. to identify your motorcycle and may be
MODEL LABEL INFORMATION: used to register your motorcycle with
8 the licensing authority in your area.

9-1

5YR-F8199-10ch9.pmd 1 2003/10/27, 19:34

 CONSUMER INFORMATION
EAU26460
Model label

1 1

ZAUM00** 4

1. Model label
5
The model label is affixed to the loca-
tion shown. Record the information on
6
this label in the space provided. This
information will be needed when order-
ing spare parts from a Yamaha dealer. 7

9-2

5YR-F8199-10ch9.pmd 2 2003/10/27, 19:34

 CONSUMER INFORMATION
EAU26550

Reporting safety defects

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immedi-
ately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation,
1 U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a
group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual
2 problems between you, your dealer, or Yamaha Motor Corporation, U.S.A.

3 To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.
area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information
about motor vehicle safety from the Hotline.
4

9-3

5YR-F8199-10ch9.pmd 3 2003/10/27, 19:34

 CONSUMER INFORMATION
EAU26560

Motorcycle noise regulation

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other
than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new 1
vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use
of the vehicle after such device or element of design has been removed or rendered inoperative by any person. 2

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”. 3

These acts include tampering with the following systems; i.e., modification, removal, etc.
4

Muffler 6
Exhaust system Exhaust pipe
Silencer
7
Air cleaner case
Intake system Air cleaner element
Intake duct 8

9-4

5YR-F8199-10ch9.pmd 4 2003/10/27, 19:34

 CONSUMER INFORMATION
EAU26661

YAMAHA MOTOR CORPORATION, U.S.A.

STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY
1

9-5

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 CONSUMER INFORMATION

9-6

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 CONSUMER INFORMATION
EAU26750

YAMAHA EXTENDED SERVICE (Y.E.S.)

9-7

5YR-F8199-10ch9.pmd 7 2003/10/27, 19:34

 CONSUMER INFORMATION

9-8

5YR-F8199-10ch9.pmd 8 2003/10/27, 19:34

 INDEX
A F P
Acceleration and deceleration .................. 5-2 Final transmission oil .............................. 6-17 PERIODIC MAINTENANCE .................... 6-1
Adjusting the brake lever free play ........ 6-21 Front brake lever ...................................... 3-3 PERIODIC MAINTENANCE AND MINOR
Adjusting the carburetor ......................... 6-19 Fuel ........................................................... 3-5 REPAIR ................................................... 6-1
1 Adjusting the rear brake lever free play 6-21 Fuel gauge ................................................ 3-3 PRE-OPERATION CHECKS ................... 4-1
Adjusting the throttle cable free play ...... 6-19 Fuel tank cap ............................................ 3-4 Parking ...................................................... 5-4
Air filter and V-belt case air filter Further safe-riding points ......................... 1-5 Periodic maintenance chart for the emission
2 elements .................................................. 6-8 G control system ........................................ 6-2
B General maintenance and lubrication Pre-operation check list ........................... 4-2
Battery ..................................................... 6-22 chart ........................................................ 6-3 R
3 Braking ...................................................... 5-3 H Rear brake lever ....................................... 3-4
C Handlebar switches .................................. 3-2 Removing and installing panels ................ 6-6
CONSUMER INFORMATION ................. 9-1 Helmet holder ............................................ 3-6 Replacing a turn signal light bulb ............ 6-11
4 Care .......................................................... 7-1 I Replacing the fuse .................................. 6-23
Carrier ....................................................... 3-8 INSTRUMENT AND CONTROL Replacing the headlight bulb .................. 6-16
Cast wheels ............................................ 6-21 FUNCTIONS .......................................... 3-1 Replacing the tail/brake light bulb ........... 6-11
5 Catalytic converter ................................... 3-5 Identification numbers .............................. 9-1 Reporting safety defects .......................... 9-3
Changing the brake fluid ......................... 6-13 Ignition circuit cut-off system ................... 3-9 Right view ................................................. 2-2
Checking and lubricating the cables ...... 6-14 Indicator lights ........................................... 3-2 S
6 Checking and lubricating the centerstand and SAFETY INFORMATION ......................... 1-1
K
sidestand ............................................... 6-15 Kickstarter ................................................ 3-6 SCOOTER CARE AND STORAGE ........ 7-1
Checking and lubricating the throttle grip and L SPECIFICATIONS .................................... 8-1
7 cable ...................................................... 6-14 Seat ........................................................... 3-6
Left view .................................................... 2-1
Checking the brake fluid level ................ 6-13 Location of important labels ..................... 1-6 Sidestand .................................................. 3-8
Checking the front brake pads and rear brake Speedometer unit ..................................... 3-3
8 shoes .................................................... 6-12
Lubricating the front and rear brake
Starting a cold engine ............................... 5-1
levers .................................................... 6-14
Checking the front fork ........................... 6-15 Luggage hook ........................................... 3-8 Starting off ................................................. 5-2
9 Checking the spark plug .......................... 6-7 Storage ...................................................... 7-3
M
Checking the steering ............................ 6-16 Storage compartment ............................... 3-7
Main switch/steering lock ......................... 3-1
Controls and instruments ......................... 2-3 T
Motorcycle noise regulation ..................... 9-4
D Tires ........................................................ 6-19
O
DESCRIPTION ......................................... 2-1 Troubleshooting ...................................... 6-26
OPERATION AND IMPORTANT RIDING
E Troubleshooting chart ............................. 6-27
POINTS ................................................... 5-1
Engine break-in ......................................... 5-3 Owner’s tool kit ......................................... 6-1
Engine oil and oil strainer ........................ 6-24

5YR-F8199-10idx.pmd 1 2003/10/30, 11:58

 INDEX
Y
YAMAHA EXTENDED SERVICE (Y.E.S.) 9-7
YAMAHA MOTOR CORPORATION, U.S.A
STREET AND ENDURO MOTORCYCLE
LIMITED WARRANTY ............................ 9-5 1

5YR-F8199-10idx.pmd 2 2003/10/27, 19:42

 INDEX

5YR-F8199-10idx.pmd 3 2003/10/27, 19:42

 INDEX

5YR-F8199-10idx.pmd 4 2003/10/27, 19:42

1

YAMAHA MOTOR TAIWAN CO., LTD

PRINTED IN TAIWAN
2003.11-0.8 1 !
(E)

5YR-F8199-10cv.pmd 2 2003/10/27, 19:35