5ml f8199 E2

1
OWNER’S MANUAL8
9
XC125
PRINTED IN TAIWAN
2005・9−0.3×1 ! 5ML-F8199-E2
(E)
5ML-F8199-E2cv.pmd 3 2005/08/01, 10:04

1
5ML-F8199-E2ch0.pmd 1 2005/07/22, 11:31

EAU10050
INTRODUCTION
EAU10110
Welcome to the Yamaha world of motorcycling!
As the owner of the CYGNUS X, you are benefiting from Yamaha’s vast experience and newest technology regarding the
design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. 1
Please take the time to read this manual thoroughly, so as to enjoy all advantages of your CYGNUS X. The owner’s manual 2
does not only instruct you in how to operate, inspect and maintain your scooter, but also in how to safeguard yourself and
others from trouble and injury.
3
In addition, the many tips given in this manual will help keep your scooter in the best possible condition. If you have any
further questions, do not hesitate to contact your Yamaha dealer. 4
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first! 5
5ML-F8199-E2ch0.pmd 2 2005/07/22, 11:31

EAU10120
IMPORTANT MANUAL INFORMATION

EAU34111
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
4 cC A CAUTION indicates special precautions that must be taken to avoid damage to the scooter.
5
NOTE: A NOTE provides key information to make procedures easier or clearer.
6
NOTE:
7 8 This manual should be considered a permanent part of this scooter and should remain with it even if the scooter is
subsequently sold.
8 Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most
8 current product information available at the time of printing, there may be minor discrepancies between your scooter and
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.
*Product and specifications are subject to change without notice.
5ML-F8199-E2ch0.pmd 3 2005/07/22, 11:31

IMPORTANT MANUAL INFORMATION
EAUT1390
7
CYGNUS X
OWNER’S MANUAL
©2005 by Yamaha Motor Taiwan Co., Ltd. 8
1st edition, September 2005
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.
5ML-F8199-E2ch0.pmd 4 2005/07/22, 11:31

EAU10210
TABLE OF CONTENTS
SAFETY INFORMATION ....... 1-1 Sidestand switch operation Engine oil and oil strainer ...... 6-8
Further safe-riding points ..... 1-4 check ............................... 3-10 Final transmission oil .......... 6-10
Air filter and V-belt case air filter
1 DESCRIPTION ....................... 2-1 PRE-OPERATION CHECKS . 4-1 elements .......................... 6-11
Left view ............................... 2-1 Pre-operation check list ........ 4-2 Adjusting the carburetor ..... 6-13
2 Right view ............................. 2-2 Adjusting the throttle cable free
Controls and instruments ..... 2-3 OPERATION AND IMPORTANT play .................................. 6-14
3 RIDING POINTS .................... 5-1 Valve clearance .................. 6-14
INSTRUMENT AND CONTROL Starting a cold engine ........... 5-1 Tires ................................... 6-15
FUNCTIONS........................... 3-1 Starting off ............................ 5-2 Cast wheels ....................... 6-17
4
Main switch/steering lock ..... 3-1 Acceleration and Checking the front brake lever
Indicator lights ...................... 3-2 deceleration ....................... 5-2 free play ........................... 6-17
5
Speedometer unit ................. 3-3 Braking ................................. 5-2 Adjusting the rear brake lever
Fuel gauge ............................ 3-3 Tips for reducing fuel consump- free play ........................... 6-18
6 Handlebar switches .............. 3-3 tion ..................................... 5-3 Checking the front brake pads
Front brake lever .................. 3-4 Engine break-in .................... 5-3 and rear brake shoes ...... 6-18
7 Rear brake lever ................... 3-4 Parking ................................. 5-4 Checking the front brake fluid
Fuel tank cap ........................ 3-5 level ................................. 6-19
8 Fuel ...................................... 3-6 PERIODIC MAINTENANCE Changing the brake fluid ..... 6-20
Catalytic converter ............... 3-6 AND MINOR REPAIR ............ 6-1 Checking and lubricating the
9 Kickstarter ............................ 3-7 Owner’s tool kit ..................... 6-1 cables .............................. 6-20
Seat ...................................... 3-7 Periodic maintenance and Checking and lubricating the
Helmet holder ....................... 3-8 lubrication chart ................. 6-3 throttle grip and cable ...... 6-21
Storage compartment ........... 3-8 Removing and installing Lubricating the front and rear
Luggage hook ....................... 3-9 panels ................................ 6-6
Sidestand ........................... 3-10 Checking the spark plug ....... 6-7
5ML-F8199-E2ch0.pmd 5 2005/07/22, 11:31

TABLE OF CONTENTS
brake levers ..................... 6-21 SPECIFICATIONS ................. 8-1
Checking and lubricating the
centerstand and CONSUMER INFORMATION 9-1
sidestand ......................... 6-21 Identification numbers .......... 9-1 1
Checking the front fork ....... 6-22
Checking the steering ........ 6-22 2
Checking the wheel
bearings ........................... 6-23 3
Battery ................................ 6-23
Replacing the fuses ............ 6-25 4
Replacing a headlight bulb .. 6-26
Replacing the tail/brake light
5
bulb .................................. 6-27
Replacing a front turn signal light
6
bulb .................................. 6-28
Rear turn signal light bulb ... 6-28
Troubleshooting .................. 6-29 7
Troubleshooting chart ......... 6-30
8
SCOOTER CARE AND STOR-
AGE ........................................ 7-1 9
Care...................................... 7-1
Storage ................................. 7-3
5ML-F8199-E2ch0.pmd 6 2005/07/22, 11:31

EAU10220
Q SAFETY INFORMATION
EAU10261
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
8 The failure of motorists to detect fied and that you only lend your
OPERATOR 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-
familiar with the scooter and all
MENTS IN THE OWNER’S
Therefore: of its controls.
7 MANUAL.
9 Wear a brightly colored jacket. Many accidents have been caused
8 OBTAIN QUALIFIED TRAINING IN
9 Use extra caution when ap- by error of the scooter operator. A
8 SAFE AND PROPER RIDING
proaching and passing through typical error made by the operator
TECHNIQUES.
intersections, since intersec- is veering wide on a turn due to
8 OBTAIN PROFESSIONAL TECH-
9 tions are the most likely places EXCESSIVE SPEED or
NICAL SERVICE AS INDICATED
for scooter 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
5ML-F8199-E2ch1.pmd 1 2005/08/25, 13:16

9 Always signal before turning or Protective apparel Modifications
changing lanes. Make sure that The majority of fatalities from scooter Modifications made to this scooter not
other motorists can see you. accidents are the result of head injuries. approved by Yamaha, or the removal of
8 The posture of the operator and The use of a safety helmet is the single original equipment, may render the 1
passenger is important for proper most critical factor in the prevention or scooter unsafe for use and may cause
control. reduction of head injuries. severe personal injury. Modifications
9 The operator should keep both 8 Always wear an approved helmet. may also make your scooter illegal to 2
hands on the handlebar and 8 Wear a face shield or goggles. Wind use.
both feet on the footboard in your unprotected eyes could con- 3
during operation to maintain tribute to an impairment of vision Loading and accessories
control of the scooter. which could delay seeing a hazard. Adding accessories or cargo to your 4
9 The passenger should always 8 The use of a jacket, substantial scooter can adversely affect stability
hold onto the operator, the seat shoes, trousers, gloves, etc., is and handling if the weight distribution of
strap or grab bar, if equipped, effective in preventing or reducing the scooter is changed. To avoid the 5
with both hands and keep both abrasions or lacerations. possibility of an accident, use extreme
feet on the passenger foot- 8 Never wear loose-fitting clothes, caution when adding cargo or accesso- 6
rests. otherwise they could catch on the ries to your scooter. Use extra care when
9 Never carry a passenger unless control levers or wheels and cause riding a scooter that has added cargo or 7
he or she can firmly place both injury or an accident. accessories. Here are some general
feet on the passenger foot- 8 Never touch the engine or exhaust guidelines to follow if loading cargo or
rests. system during or after operation. adding accessories to your scooter: 8
8 Never ride under the influence of They become very hot and can
alcohol or other drugs. cause burns. Always wear protec- 9
This scooter is designed for on-road tive clothing that covers your legs,
use only. It is not suitable for off- ankles, and feet.
road use. 8 Passengers should also observe
the above precautions.
1-2
5ML-F8199-E2ch1.pmd 2 2005/08/25, 13:16

Loading Accessories handlebar or front fork area,
The total weight of the operator, passen- Genuine Yamaha accessories have they must be as lightweight as
ger, accessories and cargo must not been specifically designed for use on possible and should be kept to
exceed the maximum load limit. this scooter. Since Yamaha cannot test a minimum.
1
all other accessories that may be avail- 9 Bulky or large accessories may
Maximum load: able, you must personally be responsible seriously affect the stability of
2 170 kg (375 lb) for the proper selection, installation and the scooter due to aerodynamic
use of non-Yamaha accessories. Use effects. Wind may attempt to
3 When loading within this weight limit, extreme caution when selecting and in- lift the scooter, or the scooter
keep the following in mind: stalling any accessories. may become unstable in cross
8 Cargo and accessory weight should Keep the following guidelines in mind, winds. These accessories may
4 be kept as low and close to the as well as those provided under “Load- also cause instability when
scooter as possible. Make sure to ing” when mounting accessories. passing or being passed by
5 distribute the weight as evenly as 8 Never install accessories or carry large vehicles.
possible on both sides of the cargo that would impair the perfor- 9 Certain accessories can
6 scooter to minimize imbalance or mance of your scooter. Carefully displace the operator from his
instability. inspect the accessory before us- or her normal riding position.
8 Shifting weights can create a sud- ing it to make sure that it does not This improper position limits
7 den imbalance. Make sure that ac- in any way reduce ground clear- the freedom of movement of
cessories and cargo are securely ance or cornering clearance, limit the operator and may limit
8 attached to the scooter before riding. suspension travel, steering travel control ability, therefore, such
Check accessory mounts and or control operation, or obscure accessories are not recom-
9 cargo restraints frequently. lights or reflectors. mended.
8 Never attach any large or heavy 9 Accessories fitted to the 8 Use caution when adding electrical
items to the handlebar, front fork, handlebar or the front fork area accessories. If electrical accesso-
or front fender. Such items can cre- can create instability due to ries exceed the capacity of the
ate unstable handling or a slow improper weight distribution or scooter’s electrical system an elec-
steering response. aerodynamic changes. If tric failure could result, which could
accessories are added to the cause a dangerous loss of lights or
1-3
5ML-F8199-E2ch1.pmd 3 2005/08/25, 13:16

EAU10371
engine power. are not likely to touch these hot
areas. Further safe-riding points
Gasoline and exhaust gas 9 Do not park the scooter on a 8 Be sure to signal clearly when mak-
8 GASOLINE IS HIGHLY FLAM- slope or soft ground, otherwise ing turns.
1
MABLE: it may fall over.
9 Always turn the engine off 9 Do not park the scooter near a
when refueling. flammable source (e.g., a 2
9 Take care not to spill any kerosene heater, or near an
gasoline on the engine or open flame), otherwise it could 3
exhaust system when refueling. catch fire.
9 Never refuel while smoking or 8 If you should swallow any gasoline, 4
in the vicinity of an open flame. inhale a lot of gasoline vapor, or
8 Never start the engine or let it run allow gasoline to get into your eyes,
for any length of time in a closed see your doctor immediately. If any
ZAUM00**
5
area. The exhaust fumes are poi- gasoline spills on your skin or cloth- Turn left
sonous and may cause loss of con- ing, immediately wash the affected 6
sciousness and death within a area with soap and water and
short time. Always operate your change your clothes. 7
scooter in an area that has adequate
ventilation.
8 Always turn the engine off before 8
leaving the scooter unattended and
remove the key from the main 9
switch. When parking the scooter,
note the following: ZAUM00**
9 The engine and exhaust

system may be hot, therefore, Turn right
park the scooter in a place
where pedestrians or children
1-4
5ML-F8199-E2ch1.pmd 4 2005/08/25, 13:16

8 Braking can be extremely difficult
on a wet road. Avoid hard braking,
because the scooter could slide.
Apply the brakes slowly when stop-
1
ping on a wet surface.
8 Slow down as you approach a cor-
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,
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 pads could get wet when
you wash the scooter. After wash-
8 ing the scooter, check the brakes
before riding.
9 8 Always wear a helmet, gloves, trou-
sers (tapered around the cuff and
ankle so they do not flap), and a
bright colored jacket.
8 Do not carry too much luggage on
the scooter. An overloaded scooter
is unstable.
1-5
5ML-F8199-E2ch1.pmd 5 2005/08/25, 13:16

1-6
5ML-F8199-E2ch1.pmd 6 2005/08/25, 13:16

EAU10400
DESCRIPTION
EAU10410
Left view
2 3
3 1 2
9
4
5
4
8
8 7 6
9 1. Luggage hook
2. Battery(Page:6-23) 5
3. Storage compartment(Page:3-8)
4. Tail/brake light(Page:6-27)
5. Rear turn signal light(Page:6-28)
6. Air filter(Page:6-11)
7. Kickstarter(Page:3-7)
8. V-belt case air filter(Page:6-11)
9. Fuel tank cap(Page:3-5)
2-1
5ML-F8199-E2ch2.pmd 1 2005/07/22, 11:32

DESCRIPTION
EAU10420
Right view
1
5 1
2 5
3 6
7
4
8
1. Front turn signal light(Page6-28)

2. Main fuse(Page:6-25)
3. Headlight(Page:6-26)
4. Centerstand(Page:6-21)
5. Fuse box(Page:6-25)
2-2
5ML-F8199-E2ch2.pmd 2 2005/07/22, 11:32

DESCRIPTION
EAU10430
Controls and instruments
2
2 4 6
3 5
3
5 1 7
6
8
7
9 1.Rear brake lever (Page3-4)

2.Left handlebar switches(Page:3-3)
3.Indicator lights(Page:3-2)
4.Speedometer unit(Page:3-3)
5.Fuel gauge(Page:3-3)
6.Right handlebar switches(Page:3-3)
7.Front brake lever(Page:3-4)
8.Main switch(Page:3-1)
2-3
5ML-F8199-E2ch2.pmd 3 2005/07/22, 11:32

EAU10445
INSTRUMENT AND CONTROL FUNCTIONS

EAU10460 EAU10660
To unlock the steering
Main switch/steering lock OFF
All electrical systems are off. The key
can be removed.
EAU10680 1
F ON
OF LOCK 1 2
The steering is locked, and all electrical 2
systems are off. The key can be re-
moved.
To lock the steering 3
ZAUM00**
ZAUM00**
4
The main switch/steering lock controls F ON 1 1. Turn
OF
2. Release 5
the ignition and lighting systems, and is
used to lock the steering. The various Push the key in, and then turn it to “OFF”
positions are described below. while still pushing it. 6
EWA10060
ON
EAUT1422
w
ZAUM00**
Never turn the key to “OFF” or 7
All electrical circuits are supplied with
power; the meter lighting, taillight, and 1. Push “LOCK” while the vehicle is moving,
auxiliary light come on, and the engine otherwise the electrical systems will 8
1. Turn the handlebars all the way to be switched off, which may result in
can be started. The key cannot be re- the left.
moved. loss of control or an accident. Make 9
2. Push the key in from the “OFF” po- sure that the vehicle is stopped be-
NOTE: sition, and then turn it to “LOCK” fore turning the key to “OFF” or
The headlights come on automatically while still pushing it. “LOCK”.
when the engine is started and stay on 3. Remove the key.
until the key is turned to “OFF” or the
sidestand is moved down.
3-1
5ML-F8199-E2ch3.pmd 1 2005/08/25, 13:17

EAU10980 ECA10280
After changing the engine oil, reset the
Indicator lights oil change indicator switch by pushing cC
it in. After 1000 km (600 mi) of operation,
1 2 the engine oil must be changed.
1
1
2
3
2
4 ZAUM00**
ZAUM00**
5 1. High beam indicator light ”&”

2. Turn signal indicator light “5” 1. Oil change indicator
EAU11020 2. Reset switch
6 Turn signal indicator light “5 5”
This indicator light flashes when the turn If the engine oil is changed before the
signal switch is pushed to the left or right. 3000 km (1800 mi) interval, the indica-
7 tor must be reset after the oil change
EAU11080
for the next periodic oil change to be
High beam indicator light “& &”
8 indicated at the correct time.
This indicator light comes on when the
high beam of the headlight is switched
9 on. NOTE:
EAUT1370 After resetting the oil change indicator
Oil change indicator switch, the indicator changes from red
This indicator changes from green to red to green.
every 3000 km (1800 mi) to indicate that
the engine oil should be changed.
3-2
5ML-F8199-E2ch3.pmd 2 2005/08/25, 13:17

EAU11620 EAU12150 EAU12343
Speedometer unit Fuel gauge Handlebar switches

The fuel gauge indicates the amount of
1 2 fuel in the fuel tank. The needle moves
towards “E” (Empty) as the fuel level 1 1
decreases. When the needle reaches the 2
red line, refuel as soon as possible. 2
NOTE:
Do not allow the fuel tank to empty it- 3
self completely.
3
ZAUM00**
ZAUM00**
4
1. Speedometer 1. Dimmer switch “%/&“

2. Turn signal switch “4/6”
5
2. Fuel gauge
3. Horn switch “*”
The speedometer unit is equipped with 6
a speedometer and an odometer. The
speedometer shows riding speed. The
odometer shows the total distance trav- 7
eled.
8
1 9
ZAUM00**
1. Start switch “,”
3-3
5ML-F8199-E2ch3.pmd 3 2005/08/25, 13:17

EAU12400 EAU12900 EAU12950
Dimmer switch “% %/&&” Front brake lever Rear brake lever
Set this switch to “&” for the high beam
and to “%” for the low beam. 1 1
1 EAU12460
Turn signal switch “4 4/6 6”
To signal a right-hand turn, push this
2
switch to “4”. To signal a left-hand turn,
push this switch to “6”. When released,
3 the switch returns to the center position.
To cancel the turn signal lights, push the
4 switch in after it has returned to the cen-
ZAUM00** ZAUM00**
ter position.
5 EAU12500 1. Front brake lever 1. Rear brake lever
Horn switch “* *”
Press this switch to sound the horn. The front brake lever is located on the The rear brake lever is located on the
6 right handlebar grip. To apply the front left handlebar grip. To apply the rear
EAU12720 brake, pull this lever toward the handle- brake, pull this lever toward the handle-
,”
Start switch “, bar grip. bar grip.
7 With the sidestand up, push this switch
while applying the front or rear brake to
8 crank the engine with the starter.
ECA10050
cC
9
See page 5-1 for starting instructions
prior to starting the engine.
3-4
5ML-F8199-E2ch3.pmd 4 2005/08/25, 13:17

EAUT1382
2. Turn the key clockwise to the origi-
Fuel tank cap nal position, and then remove it.
To remove the fuel tank cap
NOTE:
Open the lid by pulling the lever up. In-
The fuel tank cap cannot be installed 1
sert the key into the fuel tank cap lock
1 unless the key is in the lock. In addi-
and turn it 1/4 turn counterclockwise. The
tion, the key cannot be removed if the
lock will be released and the fuel tank 2
cap is not properly installed and locked.
cap can be removed.
2
3
ZAUM00**
3. Close the lid.
EWA10130
1. Fuel tank cap

w 4
2. Fuel tank cap holder Make sure that the fuel tank cap is
1
properly installed before riding. 5
To install the fuel tank cap
1. Insert the fuel tank cap into the fuel
tank opening with the key inserted 6
in the lock and the match marks
ZAUM00**
aligned.
7
1. Lid
1 8
NOTE:
After removing the fuel tank cap, place
it into the fuel tank cap holder as shown. 9
ZAUM00**
1. Match marks
3-5
5ML-F8199-E2ch3.pmd 5 2005/08/25, 13:17

EAU13210 EAU13431
deteriorate painted surfaces or plas-
Fuel tic parts. Catalytic converter
This model is equipped with a catalytic
EAU33520
converter in the exhaust system.
1 Recommended fuel:
EWA10860
1 w
REGULAR UNLEADED GASO-
2 LINE ONLY The exhaust system is hot after op-
Fuel tank capacity: eration. Make sure that the exhaust
7.1 L (1.88 US gal) (1.56 Imp.gal) system has cooled down before do-
3
ing any maintenance work.
ECA11400
4 ZAUM00**
cC ECA10700
Use only unleaded gasoline. The use cC
1. Fuel level of leaded gasoline will cause severe
5 The following precautions must be
damage to internal engine parts, such
Make sure that there is sufficient fuel in observed to prevent a fire hazard or
as the valves and piston rings, as well
6 the tank. Fill the fuel tank to the bottom other damages.
as to the exhaust system.
of the filler tube as shown. 8 Use only unleaded gasoline. The
EWA10880
use of leaded gasoline will cause
7 w Your Yamaha engine has been designed unrepairable damage to the cata-
8 Do not overfill the fuel tank, oth- to use regular unleaded gasoline with a lytic converter.
8 erwise it may overflow when the research octane number of 91 or higher. 8 Never park the vehicle near pos-
fuel warms up and expands. If knocking (or pinging) occurs, use a sible fire hazards such as grass
8 Avoid spilling fuel on the hot gasoline of a different brand or premium or other materials that easily
9 unleaded fuel. Use of unleaded fuel will
engine. burn.
extend spark plug life and reduce main- 8 Do not allow the engine to idle
ECA10070 tenance costs. too long.
cC
Immediately wipe off spilled fuel with
a clean, dry, soft cloth, since fuel may
3-6
5ML-F8199-E2ch3.pmd 6 2005/08/25, 13:17

EAU13680 EAU13931
Kickstarter Seat NOTE:

Make sure that the seat is properly se-
To open the seat
cured before riding.
1. Place the scooter on the
centerstand. 1
2. Insert the key into the main switch,
and then turn it counterclockwise. 2
3
1 F ON
OF
ZAUM00**
4
1. Kickstarter
To start the engine, fold out the 5

kickstarter lever, move it down lightly
with your foot until the gears engage, 6
ZAUM00**
and then push it down smoothly but

forcefully. 7
NOTE:
Do not push inward when turning the key.
8
3. Fold the seat up.
To close the seat 9
1. Fold the seat down, and then push
it down to lock it in place.
2. Remove the key from the main
switch if the scooter will be left un-
attended.
3-7
5ML-F8199-E2ch3.pmd 7 2005/08/25, 13:17

EAU14300 EAU14510
To release the helmet from the hel-
Helmet holder met holder Storage compartment
Open the seat, remove the helmet from
1
the helmet holder, and then close the 1
seat.
4 ZAUM00**
1 ZAUM00**
1. Helmet holder 1. Storage compartment

5
The helmet holder is located under the There is a storage compartment under
6 seat. the seat. (See page 3-7.)
EWA10960
To secure a helmet to the helmet
holder w
7 1. Open the seat. (See page 3-7.) 8 Do not exceed the load limit of 5
2. Attach the helmet to the helmet kg (11 lb) for the storage com-
8 holder, and then securely close the partment.
seat. 8 Do not exceed the maximum
EWA10160 load of 170 kg (375 lb) for the ve-
9 w hicle.
Never ride with a helmet attached to
the helmet holder, since the helmet ECA10080
may hit objects, causing loss of con- cC

trol and possibly an accident. Keep the following points in mind
when using the storage compart-
3-8
5ML-F8199-E2ch3.pmd 8 2005/08/25, 13:17

ment. 8 Do not leave your scooter unat- EAUT1070
8 Since the storage compartment tended with the seat open. Luggage hook
accumulates heat when exposed
to the sun, do not store anything 1
susceptible to heat inside it.
8 To avoid humidity from spread-
ing through the storage compart- 1 2
ment, wrap wet articles in a plas-
tic bag before storing them in the 3
compartment.
8 Since the storage compartment 4
ZAUM00**
may get wet while the scooter is
being washed, wrap any articles 1. Luggage hook
stored in the compartment in a EWAT1030 5
plastic bag. w
8 Do not keep anything valuable or 8 Do not exceed the load limit of 3 6
breakable in the storage com- kg (7 lb) for the luggage hook.
partment. 8 Do not exceed the maximum
7
load of 170 kg (375 lb) for the ve-
hicle.
To store a helmet in the storage com-
8
partment, place the helmet upside-down
with the front facing forward.
9
NOTE:
8 Some helmets cannot be stored in
the storage compartment because
of their size or shape.
3-9
5ML-F8199-E2ch3.pmd 9 2005/08/25, 13:17

EAU15301 EAUT1091
have a Yamaha dealer repair it if it
Sidestand does not function properly. Sidestand switch operation
The sidestand is located on the left side check
of the frame. Raise the sidestand or lower Check the operation of the sidestand
1 it with your foot while holding the motor- switch against the information below.
cycle upright. EWA10260
2 w
NOTE: 8 The vehicle must be placed on
3 The built-in sidestand switch is part of the centerstand during this in-
the ignition circuit cut-off system, which spection.
cuts the ignition in certain situations. 8 If a malfunction is noted, have a
4 Yamaha dealer check the system
(See further down for an explanation of
the ignition circuit cut-off system.) before riding.
5
EWA10240
6 w
The vehicle must not be ridden with
7 the sidestand down, or if the
sidestand cannot be properly moved
up (or does not stay up), otherwise
8 the sidestand could contact the
ground and distract the operator, re-
9 sulting in a possible loss of control.
Yamaha’s ignition circuit cut-off sys-
tem has been designed to assist the
operator in fulfilling the responsibil-
ity of raising the sidestand before
starting off. Therefore, check this sys-
tem regularly as described below and
3-10
5ML-F8199-E2ch3.pmd 10 2005/08/25, 13:17

Turn the key on.
Put the sidestand up. 1
Push the start switch while applying 2

either of the brake levers. The engine will
start. 3
Put the sidestand down. 4
5
If the engine stalls:
6
The sidestand switch is OK.
3-11
5ML-F8199-E2ch3.pmd 11 2005/08/25, 13:17

EAU15580
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
5ML-F8199-E2ch4.pmd 1 2005/07/22, 11:32

EAU15603
Pre-operation check list

ITEM CHECKS PAGE
• Check fuel level in fuel tank. 1
Fuel • Refuel if necessary. 3-6
• Check fuel line for leakage.
• Check oil level in engine. 2
Engine oil • If necessary, add recommended oil to specified level. 6-8
• Check vehicle for oil leakage.
Final transmission oil • Check vehicle for oil leakage. 6-10 3
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear. 4
Front brake • Replace if necessary. 6-18, 6-19
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level. 5
• Check hydraulic system for leakage.
• Lubricate cable if necessary. 6
Rear brake 6-18, 6-19
• Check lever free play.
• Adjust if necessary.
7
• Make sure that operation is smooth.
• Check cable free play.
Throttle grip 6-14, 6-21
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
8
grip housing.
• Check for damage.
• Check tire condition and tread depth. 9
Wheels and tires 6-15, 6-17
• Check air pressure.
• Correct if necessary.
Brake levers 6-21
• Lubricate lever pivoting points if necessary.
4-2
5ML-F8199-E2ch4.pmd 2 2005/07/22, 11:32

ITEM CHECKS PAGE
Centerstand, sidestand 6-21
• Lubricate pivots if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
1 Chassis fasteners -
• Tighten if necessary.
Instruments, lights, signals • Check operation.
-
and switches • Correct if necessary.
2
• Check operation of ignition circuit cut-off system.
Sidestand switch 3-10
• If system is defective, have Yamaha dealer check vehicle.
3
4-3
5ML-F8199-E2ch4.pmd 3 2005/07/22, 11:32

EAU15942
OPERATION AND IMPORTANT RIDING POINTS

EAU15980 EAUT1100 ECA11040
EWA10870
Starting a cold engine cC
w ECA10250
8 Become thoroughly familiar with For maximum engine life, never ac-
cC celerate hard when the engine is cold!
all operating controls and their See page 5-3 for engine break-in in- 1
functions before riding. Consult structions prior to operating the ve-
a Yamaha dealer regarding any hicle for the first time. 2
control or function that you do
not thoroughly understand.
1. Turn the key to “ON”. 3
8 Never start the engine or operate
2. Close the throttle grip completely.
it in a closed area for any length
3. Start the engine by pushing the
of time. Exhaust fumes are poi- 4
star t switch or by kicking the
sonous, and inhaling them can
kickstarter, while applying the front
cause loss of consciousness and 5
or rear brake.
death within a short time. Always
make sure that there is adequate NOTE:
ventilation. If the engine fails to start by pushing 6
8 For safety, always start the engine the start switch, release the switch, wait
with the centerstand down. a few seconds, and then try again. Each 7
starting attempt should be as short as
possible to preserve the battery. Do not
8
crank the engine more than 5 seconds
on any one attempt. If the engine does
not start with the starter motor, try us- 9
ing the kickstarter.
5-1
5ML-F8199-E2ch5.pmd 1 2005/07/22, 11:32

EAU16760 EAU16780 EAU16791
Starting off Acceleration and deceleration Braking

NOTE: 1. Close the throttle completely.
Before starting off, allow the engine to 2. Apply both front and rear brakes si-
1 multaneously while gradually in-
warm up.
(b) creasing the pressure.
EWA10300
2
1. While pulling the rear brake lever w
with your left hand and holding the 8 Avoid braking hard or suddenly
3 grab bar with your right hand, push (especially when leaning over to
the scooter off the centerstand. one side), otherwise the scooter
2. Sit astride the seat, and then ad-
(a)
4 ZAUM00** may skid or overturn.
just the rear view mirrors. 8 Railroad crossings, streetcar
3. Switch the turn signal on. The speed can be adjusted by opening rails, iron plates on road con-
5
4. Check for oncoming traffic, and and closing the throttle. To increase the struction sites, and manhole cov-
then slowly turn the throttle grip (on speed, turn the throttle grip in direction ers become extremely slippery
6 the right) in order to take off. (a). To reduce the speed, turn the throttle when wet. Therefore, slow down
5. Switch the turn signal off. grip in direction (b). when approaching such areas
7 and cross them with caution.
8 Keep in mind that braking on a
8 wet road is much more difficult.
8 Ride slowly down a hill, as brak-
ing downhill can be very difficult.
9
5-2
5ML-F8199-E2ch5.pmd 2 2005/07/22, 11:32

EAU16820 EAU16830
150~500 km (90~300 mi)
Tips for reducing fuel con- Engine break-in Avoid prolonged operation above 1/2
sumption There is never a more important period throttle.
Fuel consumption depends largely on in the life of your engine than the period Rev the engine freely through the gears,
between 0 and 1000 km (600 mi). For 1
your riding style. Consider the following but do not use full throttle at any time.
tips to reduce fuel consumption: this reason, you should read the follow-
8 Avoid high engine speeds during ing material carefully. 500~1000 km (300~600 mi) 2
acceleration. Avoid prolonged operation above 3/4
8 Avoid high engine speeds with no Since the engine is brand new, do not throttle. 3
load on the engine. put an excessive load on it for the first ECA10350
8 Turn the engine off instead of let- 1000 km (600 mi). The various parts in cC
the engine wear and polish themselves 4
ting it idle for an extended length of After 1000 km (600 mi) of operation,
time (e.g., in traffic jams, at traffic to the correct operating clearances. Dur- the engine oil must be changed and
lights or at railroad crossings). ing this period, prolonged full-throttle the oil strainer cleaned. 5
operation or any condition that might
result in engine overheating must be 6
1000 km (600 mi) and beyond
avoided.
EAU16950
Avoid prolonged full-throttle operation.
0~150 km (0~90 mi) Vary the speed occasionally. 7
ECA10270
Avoid prolonged operation above 1/3
throttle.
cC
8
After every hour of operation, stop the If any engine trouble should occur
engine, and then let it cool for five to during the engine break-in period,
ten minutes. immediately have a Yamaha dealer 9
Vary the engine speed from time to time. check the vehicle.
Do not operate the engine at one set
throttle position.
5-3
5ML-F8199-E2ch5.pmd 3 2005/07/22, 11:32

EAU17212
Parking
When parking, stop the engine, and then
remove the key from the main switch.
1 EWA10310
w
2 8 Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
3
ans or children are not likely to
touch them.
4 8 Do not park on a slope or on soft
ground, otherwise the vehicle
5 may overturn.
ECA10380
6 cC
Never park in an area where there are
7 fire hazards such as grass or other
flammable materials.
8
5-4
5ML-F8199-E2ch5.pmd 4 2005/07/22, 11:32

EAU17224
PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17280 EWA10330 EAU17520
Safety is an obligation of the owner. w Owner’s tool kit
Periodic inspection, adjustment and lu- This scooter is designed for use on
brication will keep your vehicle in the paved roads only. If this scooter is
safest and most efficient condition pos- 1
operated in abnormally dusty, muddy
sible. The most important points of in- or wet conditions, the air filter ele- 1
spection, adjustment, and lubrication are ment should be cleaned or replaced 2
explained on the following pages. more frequently, otherwise rapid en-
The intervals given in the periodic main- gine wear may result. Consult a 3
tenance and lubrication chart should be Yamaha dealer for proper mainte-
simply considered as a general guide nance intervals.
under normal riding conditions. However, ZAUM00**
4
DEPENDING ON THE WEATHER, TER-
RAIN, GEOGRAPHICAL LOCATION, 1. Owner’s tool kit
5
AND INDIVIDUAL USE, THE MAINTE- The owner’s tool kit is located inside the
NANCE INTERVALS MAY NEED TO BE storage compartment under the seat. 6
SHORTENED. (See page 3-7.)
EWA10320
The service information included in this
w 7
manual and the tools provided in the
If you are not familiar with mainte- owner’s tool kit are intended to assist
nance work, have a Yamaha dealer do you in the performance of preventive 8
it for you. maintenance and minor repairs. How-
ever, additional tools such as a torque 9
wrench may be necessary to perform
certain maintenance work correctly.
6-1
5ML-F8199-E2ch6.pmd 1 2005/08/25, 13:17

NOTE:
If you do not have the tools or experi-
ence required for a particular job, have
1 a Yamaha dealer perform it for you.
EWA10350
2
w
Modifications not approved by
3 Yamaha may cause loss of perfor-
mance and render the vehicle unsafe
4 for use. Consult a Yamaha dealer be-
fore attempting any changes.
5
6-2
5ML-F8199-E2ch6.pmd 2 2005/08/25, 13:17

EAU17710
Periodic maintenance and lubrication chart

NOTE:
8 The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
1
stead.
8 From 30000 km, repeat the maintenance intervals starting from 6000 km.
8 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical 2
skills.
3
ODOMETER READING (× 1,000 km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB
1 6 12 18 24 CHECK
4
1 * Fuel line • Check fuel hoses and vacuum hose for cracks or damage. √ √ √ √ √
• Check condition.
√ √ 5
2 Spark plug • Clean and regap.
• Replace. √ √
3 Valves
• Check valve clearance.
√ √ √ √ 6
* • Adjust.
• Clean. √ √
4 Air filter element 7
• Replace. √ √
V-belt case air filter
5 • Clean. √ √ √ √
element 8
• Check operation, fluid level and vehicle for fluid leakage. √ √ √ √ √ √
6 * Front brake
• Replace brake pads. Whenever worn to the limit
• Check operation and adjust brake lever free play. √ √ √ √ √ √
9
7 * Rear brake
• Replace brake shoes. Whenever worn to the limit
• Check for cracks or damage. √ √ √ √ √
8 * Brake hose
• Replace. Every 4 years
6-3
5ML-F8199-E2ch6.pmd 3 2005/08/25, 13:17

1 6 12 18 24 CHECK
9 * Wheels • Check runout and for damage. √ √ √ √
1 • Check tread depth and for damage.
• Replace if necessary.
10 * Tires √ √ √ √ √
• Check air pressure.
2 • Correct if necessary.
11 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √
• Check bearing play and steering for roughness. √ √ √ √ √
3 12 * Steering bearings
• Lubricate with lithium-soap-based grease. Every 24000 km
13 * Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. √ √ √ √ √
4
14 Sidestand, centerstand √ √ √ √ √
• Lubricate.
5 15 * Sidestand switch • Check operation. √ √ √ √ √ √
16 * Front fork • Check operation and for oil leakage. √ √ √ √
6 17
Shock absorber
• Check operation and shock absorber for oil leakage. √ √ √ √
* assembly
18 * Carburetor • Adjust engine idling speed. √ √ √ √ √ √
7
• Change. (see page 3-2) √ Every 3000 km
19 * Engine oil
• Check oil level and vehicle for oil leakage. Every 3000 km √
8 20 Engine oil strainer • Clean. √
*
• Check vehicle for oil leakage. √ √ √
21 Final transmission oil
9 • Change. √ √ √
22 * V-belt • Replace. Every 18000 km
Front and rear brake
23 * • Check operation. √ √ √ √ √ √
switches
6-4
5ML-F8199-E2ch6.pmd 4 2005/08/25, 13:17

1 6 12 18 24 CHECK
24 Moving parts and cables • Lubricate. √ √ √ √ √
Throttle grip housing

• Check operation and free play. 1
25 * • Adjust the throttle cable free play if necessary. √ √ √ √ √
and cable
• Lubricate the throttle grip housing and cable.
• Check the air cut-off valve, reed valve, and hose for 2
26 * Air induction system damage. √ √ √ √ √
• Replace the entire air induction system if necessary.
Lights, signals and • Check operation. 3
27 * √ √ √ √ √ √
switches • Adjust headlight beam.
EAU18660 4
NOTE:
8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 5
8 Hydraulic brake service
9 Regularly check and, if necessary, correct the brake fluid level.
9 Every two years replace the internal components of the brake master cylinder and caliper, and change the brake 6
fluid.
9 Replace the brake hoses every four years and if cracked or damaged. 7
6-5
5ML-F8199-E2ch6.pmd 5 2005/08/25, 13:17

EAU18771
Removing and installing pan-

1
els 1
The panels shown above need to be re-
1 2(×2)
moved to perform some of the mainte-
nance jobs described in this chapter.
2 Refer to this section each time a panel
needs to be removed and installed.
3
ZAUM00**
2 ZAUM00**
4 1 1. Panel A 1. Panel B
2. Quick fastener 2. Screw
2 To install the panel
5 To install the panel
Place the panel in the original position,
Place the panel in the original position,
3 and then install quick fasteners.
6 and then install the screws.
Panel B
Panel C
To remove the panel
ZAUM00** To remove the panel
7 Remove the screws, and then take the
Remove the screws, and then take the
1. Panel A panel off.
panel off.
2. Panel B
8 3. Panel C
EAUT1450
9 Panel A
To remove the panel
Remove the quick fasteners by push-
ing in the center pin, and then take the
panel off.
6-6
5ML-F8199-E2ch6.pmd 6 2005/08/25, 13:17

EAUT1170
To check the spark plug
Checking the spark plug 1. Check that the porcelain insulator
The spark plug is an important engine around the center electrode of the
2(×4) component, which is easy to check. spark plug is a medium-to-light tan 1
Since heat and deposits will cause any (the ideal color when the vehicle is
spark plug to slowly erode, the spark ridden normally).
plug should be removed and checked in 2
NOTE:
accordance with the periodic mainte-
If the spark plug shows a distinctly dif-
1 nance and lubrication chart. In addition, 3
ferent color, the engine could be defec-
ZAUM00** the condition of the spark plug can re-
tive. Do not attempt to diagnose such
veal the condition of the engine.
1. Panel C problems yourself. Instead, have a 4
To remove the spark plug
2. Screw Yamaha dealer check the vehicle.
1. Remove panel C. (See page 6-6.)
To install the panel 2. Remove the spark plug cap. 5
Place the panel in the original position, 3. Remove the spark plug as shown, 2. Check the spark plug for electrode
and then install the screws. with the spark plug wrench included erosion and excessive carbon or
6
in the owner’s tool kit. other deposits, and replace it if nec-
essary.
7
Specified spark plug:
CR7E (NGK) 8
To install the spark plug

1. Measure the spark plug gap with a 9
1 wire thickness gauge and, if nec-
essary, adjust the gap to specifi-
ZAUM00**
cation.
1. Spark plug wrench
6-7
5ML-F8199-E2ch6.pmd 7 2005/08/25, 13:17

EAUT1350
NOTE: Engine oil and oil strainer
If a torque wrench is not available when
The engine oil level should be checked
installing a spark plug, a good estimate
before each ride. In addition, the oil must
1 of the correct torque is 1/4~1/2 turn past
be changed and the oil strainer cleaned
finger tight. However, the spark plug
at the intervals specified in the periodic
should be tightened to the specified
2 maintenance and lubrication chart. The
torque as soon as possible.
engine oil must also be changed at the
1 initial 1000 km (600 mi) and when the
3
4. Install the spark plug cap. oil change indicator changes from green
ZAUM00**
5. Install the panel. to red. The oil change indicator must be

4 1. Spark plug gap reset after the initial 1000 km (600 mi).
(See page 3-2 for reset procedures.)
Spark plug gap:
5 0.6~0.7 mm (0.024~0.028 in)
To check the engine oil level
6 2. Clean the surface of the spark plug 1.Place the vehicle on the centerstand.
gasket and its mating surface, and NOTE:
then wipe off any grime from the Make sure that the vehicle is positioned
7
spark plug threads. straight up when checking the oil level.
3. Install the spark plug with the spark A slight tilt to the side can result in a
8 plug wrench, and then tighten it to false reading.
the specified torque.
9 2. Start the engine, warm it up for sev-
Tightening torque: eral minutes, and then turn it off.
Spark plug:
3. Wait a few minutes until the oil
13 Nm (1.3m • kgf, 9.4ft • lbf)
settles, remove the oil filler cap,
wipe the dipstick clean, insert it
back into the oil filler hole (without
6-8
5ML-F8199-E2ch6.pmd 8 2005/08/25, 13:17

screwing it in), and then remove it To change the engine oil and clean
again to check the oil level. the oil strainer
NOTE: 1. Start the engine, warm it up for sev-
The engine oil should be between the eral minutes, and then turn it off. 1
minimum and maximum level marks. 2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap and 1 2
drain bolts to drain the oil from the
crankcase. 3
ECA10410 ZAUM00**
cC
1. Engine oil drain bolt A 4
When removing the engine oil drain
bolt, the O-ring, spring, and oil
strainer will fall out. Take care not to 5
1 lose these parts.
2 6
ZAUM00**
1. Maximum level mark 7

2. Minimum level mark
1
4. If the engine oil is below the mini- 8
mum level mark, add sufficient oil ZAUM00**
of the recommended type to raise

it to the correct level. 1 1. Engine oil drain bolt B 9
5. Insert the dipstick into the oil filler 4. Clean the oil strainer with solvent,
hole, and then tighten the oil filler and then check it for damage and
cap. ZAUM00**
replace it if necessary.
1. Oil filler cap 5. Check the O-ring for damage and
replace it if necessary.
6. Install the oil strainer, spring, O-ring
6-9
5ML-F8199-E2ch6.pmd 9 2005/08/25, 13:17

EAU20060
and engine oil drain bolts, and then “ENERGY CONSERVING II” or
tighten the drain bolts to the speci- higher. Final transmission oil
fied torque. 8 Be sure no foreign material en- The final transmission case must be
ters the crankcase. checked for oil leakage before each ride.
1 If any leakage is found, have a Yamaha
Tightening torque:
Engine oil drain bolt A: dealer check and repair the scooter. In
8. Start the engine, and then let it idle
2 20 Nm (2.0 m • kgf, 14.5ft • lbf) addition, the final transmission oil must
Engine oil drain bolt B:
for several minutes while checking
be changed as follows at the intervals
20 Nm (2.0 m • kgf, 14.5 ft • lbf) it for oil leakage. If oil is leaking,
3 specified in the periodic maintenance
immediately turn the engine off and
and lubrication chart.
check for the cause.
NOTE: 1. Start the engine, warm it up by
4 9. Turn the engine off, and then check
Make sure that the O-ring is properly riding the scooter for several min-
the oil level and correct it if neces-
seated. utes, and then stop the engine.
sary.
5 2. Place the scooter on the
10. Reset the oil change indicator. (See
7. Add the specified amount of the centerstand.
page 3-2 for reset procedures.)
6 recommended engine oil, and then 3. Place an oil pan under the final
NOTE: transmission case to collect the
install and tighten the engine oil filler
If the engine oil is changed before the used oil.
7 cap.
oil change indicator changes to red (i.e. 4. Remove the oil filler cap and drain
before the periodic oil change interval bolt to drain the oil from the final
Recommended engine oil:
8 See page 8-1.
has been reached), the indicator must transmission case.
Oil change quantity: be reset after the oil change for the next
0.9 L (0.95 US qt) (0.79 Imp.qt) periodic oil change to be indicated at the
9 correct time.
ECA11670
cC
8 Do not use oils with a diesel
specification of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
6-10
5ML-F8199-E2ch6.pmd 10 2005/08/25, 13:17

EAUT1341
Tightening torque:
Final transmission oil drain bolt:
Air filter and V-belt case air fil-
23 Nm (2.3 m • kgf, 16.6 ft • lbf) ter elements
The air filter and V-belt case air filter el-
1
6. Add the specified amount of the ements should be cleaned at the inter-
recommended final transmission vals specified in the periodic mainte-
oil, and then install and tighten the nance and lubrication chart. Clean both 2
oil filler cap. filter elements more frequently if you are
1
riding in unusually wet or dusty areas. 3
ZAUM00** Recommended final transmission Cleaning the air filter element
oil: 1. Place the scooter on the
1. Final transmission oil filler cap See page 8-1. 4
centerstand.
Oil quantity: 2. Remove the air filter case cover by
5. Install the final transmission oil
0.13 L (0.14 US qt) (0.11 Imp.qt) 5
drain bolt, and then tighten it to the removing the screws.
specified torque. EWA11310
w 6
8 Make sure that no foreign mate- 2(×6)
rial enters the final transmission 7
case.
1
8 Make sure that no oil gets on the
8
tire or wheel.
1 9
7. Check the final transmission case ZAUM00**
ZAUM00**
for oil leakage. If oil is leaking,
check for the cause. 1. Air filter case cover
1. Final transmission oil drain bolt 2. Screw
3. Pull the air filter element out, and
6-11
5ML-F8199-E2ch6.pmd 11 2005/08/25, 13:17

then blow the dirt out with com- 6. Install the air filter case cover by
pressed air as shown. installing the screws.
Cleaning the V-belt case air filter ele-
ment
1
1. Remove the V-belt air filter case
cover by removing the screws.
2
3 1
1 ZAUM00**
1
4 ZAUM00**
1. Air filter element holder
3. Pull the air filter element out, and

5 1. Air filter element
then clean it with solvent. After
4. Check the air filter element for dam- 2 cleaning, remove the remaining
6 age and replace it if necessary. ZAUM00**
solvent by squeezing the element.
EWA10430
5. Insert the air filter element into the
air filter case.
1. Air filter case cover w
7 ECA10480
2. Screw
Use only a dedicated parts cleaning
cC 2. Remove the filter element holder by solvent. To avoid the risk of fire or
8 8 Make sure that the air filter ele- removing the screw. explosion, do not use gasoline or
ment is properly seated in the air solvents with a low flash point.
9 filter case.
8 The engine should never be op- ECA10520
erated without the air filter ele- cC

ment installed, otherwise the To avoid damaging the air filter ele-
piston(s) and/or cylinder(s) may ment, handle it gently and carefully,
become excessively worn. and do not twist it.
6-12
5ML-F8199-E2ch6.pmd 12 2005/08/25, 13:17

EAU21300
7. Install the V-belt air filter case cover
by installing the screws. Adjusting the carburetor
The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, all carbu- 1
retor adjustments should be left to a
Yamaha dealer, who has the necessary 2
professional knowledge and experience.
3
ZAUM00**
1
1. V-belt case air filter element 4

4. Apply oil of the recommended type
to the entire surface of the sponge 5
material, and then squeeze the ex-
cess oil out. 6
NOTE:
The air filter element should be wet but 7
not dripping.
8
Recommended oil:
Engine oil
9
5. Insert the element into the air filter
case.
6. Install the filter element holder by
installing the screw.
6-13
5ML-F8199-E2ch6.pmd 13 2005/08/25, 13:17

EAU21370 EAU21401
Adjusting the throttle cable Valve clearance

free play The valve clearance changes with use,
The throttle cable free play should mea- resulting in improper air-fuel mixture and/
1 or engine noise. To prevent this from
sure 3~5 mm (0.12~0.20 in) at the
throttle grip. Periodically check the occurring, the valve clearance must be
2 throttle cable free play and, if necessary, (a) 2 1 adjusted by a Yamaha dealer at the in-
adjust it as follows. tervals specified in the periodic mainte-
3 nance and lubrication chart.
NOTE: (b)
The engine idling speed must be cor- ZAUM00**
4 rectly adjusted before checking and ad-

1. Locknut
justing the throttle cable free play. 1. Adjusting nut
5 3. Tighten the locknut.

1. Loosen the locknut.
2. To increase the throttle cable free
6 play, turn the adjusting nut in direc-
tion (a). To decrease the throttle
7 cable free play, turn the adjusting
nut in direction (b).
8
6-14
5ML-F8199-E2ch6.pmd 14 2005/08/25, 13:17

EAU33600
Tire air pressure (measured on cold cargo, and accessories does not
Tires tires): exceed the specified maximum
To maximize the performance, durabil- 0~90 kg (0~198 lb): load for the vehicle.
ity, and safe operation of your vehicle, Front: 8 Do not carry along loosely
note the following points regarding the 175 kPa (25 psi) (1.75 kgf/cm2)
1
packed items, which can shift
specified tires. Rear: during a ride.
Tire air pressure 200 kPa (29 psi) (2.0 kgf/cm2) 2
Securely pack the heaviest items
The tire air pressure should be checked 90~170 kg (198~375 lb) to maxi-
mum load: close to the center of the vehicle
and, if necessary, adjusted before each and distribute the weight evenly 3
Front:
ride. on both sides.
EWA10500 200 kPa (29 psi) (2.0 kgf/cm2)
w Rear: 8 Adjust the tire air pressure with 4
225 kPa (33 psi) (2.25 kgf/cm2) regard to the load.
8 The tire air pressure must be Maximum load*: Check the tire condition and air
checked and adjusted on cold 170 kg (375 lb) 5
pressure before each ride.
tires (i.e., when the temperature * Total weight of rider, passenger,
of the tires equals the ambient cargo and accessories
6
temperature).
8 The tire air pressure must be EWA11200
adjusted in accordance with the w 7

riding speed and with the total Because loading has an enormous
weight of rider, passenger, cargo, impact on the handling, braking, per- 8
and accessories approved for this formance and safety characteristics
model. of your vehicle, you should keep the
following precautions in mind. 9
8 NEVER OVERLOAD THE VE-
HICLE! Operation of an over-
loaded motorcycle may result in
tire damage, loss of control, or
severe injury. Make sure that the
total weight of rider, passenger,
6-15
5ML-F8199-E2ch6.pmd 15 2005/08/25, 13:17

Tire inspection Tire information perience.
This model is equipped with tubeless
tires.
1
1
Front tire:
Size:
2 110 / 70-12 47L
2 Manufacturer/model:
CHENG SHIN/C-922N-47L
3 Rear tire:
Size:
ZAUM00**
4 120 / 70-12 58L

Manufacturer/model:
1. Tire tread depth
2. Tire sidewall CHENG SHIN/C-6007-58L
5
The tires must be checked before each EWA10470
6 ride. If the center tread depth reaches w

the specified limit, if the tire has a nail 8 Have a Yamaha dealer replace
or glass fragments in it, or if the sidewall excessively worn tires. Besides
7 is cracked, have a Yamaha dealer re- being illegal, operating the ve-
place the tire immediately. hicle with excessively worn tires
8 decreases riding stability and
Minimum tire tread depth (front and can lead to loss of control.
rear): 8 The replacement of all wheel and
9
1.6 mm (0.06 in) brake related parts, including the
tires, should be left to a Yamaha
NOTE: dealer, who has the necessary
The tire tread depth limits may differ professional knowledge and ex-
from country to country. Always comply
with the local regulations.
6-16
5ML-F8199-E2ch6.pmd 16 2005/08/25, 13:17

EAU21960 EAUT1220
been checked or repaired by a
Cast wheels Checking the front brake lever Yamaha dealer.
To maximize the performance, durabil- free play
ity, and safe operation of your motor-
cycle, note the following points regard- 1
ing the specified wheels.
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 4
wheel. A deformed or cracked wheel ZAUM0107
must be replaced. 5
8 The wheel should be balanced 1. Brake lever free play
whenever either the tire or wheel The brake lever free play should mea- 6
has been changed or replaced. An sure 3~5 mm (0.12~0.2 in) as shown.
unbalanced wheel can result in poor Periodically check the brake lever free
performance, adverse handling 7
play and, if necessary, have a Yamaha
characteristics, and a shortened dealer check the brake system.
tire life. EWA10640 8
8 Ride at moderate speeds after w
changing a tire since the tire sur- An incorrect brake lever free play in- 9
face must first be “broken in” for it dicates a hazardous condition in the
to develop its optimal characteris- brake system. Do not operate the
tics. motorcycle until the brake system has
6-17
5ML-F8199-E2ch6.pmd 17 2005/08/25, 13:17

EAU22170 EAU22380
Adjusting the rear brake lever Checking the front brake pads
free play and rear brake shoes
The front brake pads and the rear brake
1
shoes must be checked for wear at the
intervals specified in the periodic main-
2 1 tenance and lubrication chart.
(b)
EAU22420
3 (a) Front brake pads

ZAUM0320 1
4 1. Adjusting nut
EWA10650
ZAUM0108
w
5
1. Brake lever free play If proper adjustment cannot be ob-
tained as described, have a Yamaha
6 The brake lever free play should mea-
dealer make this adjustment.
sure 10~20 mm (0.39~0.79 in) as shown. 1
Periodically check the brake lever free
7
play and, if necessary, adjust it as fol- ZAUM00**
lows.
8 1. Brake pad wear indicator groove
To increase the brake lever free play,
turn the adjusting nut at the brake shoe Each front brake pad is provided with a
9 plate in direction (a). To decrease the wear indicator groove, which allows you
brake lever free play, turn the adjusting to check the brake pad wear without
nut in direction (b). having to disassemble the brake. To
check the brake pad wear, check the
wear indicator groove. If a brake pad has
worn to the point that the wear indicator
6-18
5ML-F8199-E2ch6.pmd 18 2005/08/25, 13:17

groove has almost disappeared, have a EAU32343
8 When checking the fluid level, make
Yamaha dealer replace the brake pads Checking the front brake fluid sure that the top of the master cyl-
as a set. level inder is level by turning the handle-
EAU22540 bars. 1
Rear brake shoes 8 Use only the recommended quality
1 brake fluid, otherwise the rubber
seals may deteriorate, causing 2
1 leakage and poor braking perfor-
mance. 3
Recommended brake fluid:

4
DOT 4
ZAUM00**
8 Refill with the same type of brake 5

ZAUM0059
2 1. MInimum level mark fluid. Mixing fluids may result in a
Insufficient brake fluid may allow air to harmful chemical reaction and lead 6
1. Wear indicator
2. Wear limit line enter the brake system, possibly caus- to poor braking performance.
ing it to become ineffective. 8 Be careful that water does not en-
The rear brake is provided with a wear 7
ter the master cylinder when refill-
indicator, which allows you to check the Before riding, check that the brake fluid ing. Water will significantly lower the
brake shoe wear without having to dis- is above the minimum level mark and boiling point of the fluid and may 8
assemble the brake. To check the brake replenish if necessary. A low brake fluid result in vapor lock.
shoe wear, check the position of the level may indicate worn brake pads and/ 8 Brake fluid may deteriorate painted 9
wear indicator while applying the brake. or brake system leakage. If the brake surfaces or plastic parts. Always
If a brake shoe has worn to the point fluid level is low, be sure to check the clean up spilled fluid immediately.
that the wear indicator reaches the wear brake pads for wear and the brake sys-
limit line, have a Yamaha dealer replace tem for leakage.
the brake shoes as a set. Observe these precautions:
6-19
5ML-F8199-E2ch6.pmd 19 2005/08/25, 13:17

8 As the brake pads wear, it is nor- EAU22720 EAU23100
mal for the brake fluid level to Changing the brake fluid Checking and lubricating the
gradually go down. However, if the Have a Yamaha dealer change the brake cables
brake fluid level goes down sud- fluid at the intervals specified in the The operation of all control cables and
1 NOTE after the periodic maintenance
denly, have a Yamaha dealer check the condition of the cables should be
the cause. and lubrication chart. In addition, have checked before each ride, and the
2 the oil seals of the brake master cylin- cables and cable ends should be lubri-
der and caliper as well as the brake hose cated if necessary. If a cable is dam-
3 replaced at the intervals listed below or aged or does not move smoothly, have
whenever they are damaged or leaking. a Yamaha dealer check or replace it.
8 Oil seals: Replace every two years.
4 8 Brake hose: Replace every four Recommended lubricant:
years. Engine oil
5
EWA10720
w
6
Damage to the outer sheath may in-
terfere with proper cable operation
7 and will cause the inner cable to rust.
Replace a damaged cable as soon as
8 possible to prevent unsafe condi-
tions.
9
6-20
5ML-F8199-E2ch6.pmd 20 2005/08/25, 13:17

EAU23110 EAU23170 EAU23210
Checking and lubricating the Lubricating the front and rear Checking and lubricating the
throttle grip and cable brake levers centerstand and sidestand
The operation of the throttle grip should
1
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in the 2
periodic maintenance chart.
3
4
ZAUM00** ZAUM00**
5
The pivoting points of the front and rear The operation of the centerstand and
brake levers must be lubricated at the sidestand should be checked before
6
intervals specified in the periodic main- each ride, and the pivots and metal-to-
tenance and lubrication chart. metal contact surfaces should be lubri-
cated if necessary. 7
EWA10740
Recommended lubricant:
Lithium-soap-based grease (all-pur- w 8
pose grease) If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or repair 9
it.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
6-21
5ML-F8199-E2ch6.pmd 21 2005/08/25, 13:17

EAU23271 EAU23280
Checking the front fork Checking the steering

The condition and operation of the front Worn or loose steering bearings may
fork must be checked as follows at the cause danger. Therefore, the operation
1 intervals specified in the periodic main- of the steering must be checked as fol-
tenance and lubrication chart. lows at the intervals specified in the
2 periodic maintenance and lubrication
To check the condition chart.
EWA10750
3 1. Place a stand under the engine to
w ZAUM00** raise the front wheel off the ground.
Securely support the motorcycle so EWA10750
4 that there is no danger of it falling ECA10590 w

over. cC Securely support the motorcycle so
5 If any damage is found or the front that there is no danger of it falling
Check the inner tubes for scratches, fork does not operate smoothly, have over.
damage and excessive oil leakage. a Yamaha dealer check or repair it.
6
2. Hold the lower ends of the front fork
To check the operation legs and try to move them forward
7 1. Place the motorcycle on a level sur- and backward. If any free play can
face and hold it in an upright posi- be felt, have a Yamaha dealer check
8 tion. or repair the steering.
2. While applying the front brake, push
9 down hard on the handlebars sev-
eral times to check if the front fork
compresses and rebounds
smoothly.
6-22
5ML-F8199-E2ch6.pmd 22 2005/08/25, 13:17

EAU23290 EAUT1401
Checking the wheel bearings Battery

The front and rear wheel bearings must This model is equipped with a sealed-
be checked at the intervals specified in type (MF) battery, which does not re-
the periodic maintenance and lubrication quire any maintenance. There is no need 1
chart. If there is play in the wheel hub or to check the electrolyte or to add dis-
if the wheel does not turn smoothly, tilled water. 2
ECA10630
have a Yamaha dealer check the wheel
bearings. cC
3
ZAUM00**
8 Always keep the battery charged.
Storing a discharged battery can
cause permanent battery dam- 4
age.
8 To charge a sealed-type (MF) bat- 5
tery, a special (constant-voltage)
battery charger is required. Us- 6
ing a conventional battery
charger will damage the battery.
If you do not have access to a 7
sealed-type (MF) battery charger,
have a Yamaha dealer charge 8
your battery.
9
EWA10760
w
8 Electrolyte is poisonous and dan-
gerous since it contains sulfuric
acid, which causes severe burns.
6-23
5ML-F8199-E2ch6.pmd 23 2005/08/25, 13:17

Avoid any contact with skin, eyes have discharged. Keep in mind that the
or clothing and always shield battery tends to discharge more quickly
your eyes when working near if the vehicle is equipped with optional
batteries. In case of contact, ad- electrical accessories.
1 1
minister the following FIRST AID. To store the battery
9 EXTERNAL: Flush with 1. If the vehicle will not be used for
2 plenty of water. more than one month, remove the
9 INTERNAL: Drink large battery, fully charge it, and then
3 quantities of water or milk place it in a cool, dry place.
and immediately call a 2. If the battery will be stored for more ZAUM00**
physician. than two months, check it at least

4 1. Panel
9 EYES: Flush with water for once a month and fully charge it if
2. Remove the battery holder bracket
15 minutes and seek prompt necessary.
5 by removing the bolt.
medical attention. To remove the battery
8 Batteries produce explosive hy- 1. Remove the panel by removing the
6 drogen gas. Therefore, keep screw. 1
sparks, flames, cigarettes, etc.,
away from the battery and pro-
7
vide sufficient ventilation when
charging it in an enclosed space.
8 8 KEEP THIS AND ALL BATTERIES
OUT OF THE REACH OF CHIL-
9 DREN. ZAUM00**
To charge the battery 1. Bracket

Have a Yamaha dealer charge the bat- 3. Pull the battery out from the bat-
tery as soon as possible if it seems to tery box, and then disconnect the
battery couplers.
6-24
5ML-F8199-E2ch6.pmd 24 2005/08/25, 13:17

EAUT1431
Replacing the fuses

1 The main fuse box is located behind
panel B. (See page 6-6.) 1
1
2
2 3
45
3
6
ZAUM00** ZAUM00**
1. Battery 1 1. Lid 4
2. Fuse box
To install the battery 3. Carburetor heater fuse
1. Connect the battery couplers, and
ZAUM00**
4. Ignition fuse 5
then place the battery in the origi- 5. Headlight fuse
1. Main fuse 6. Signaling system fuse
nal position. 6
2. Install the battery holder bracket by The fuse block, which contains the fuses If a fuse is blown, replace it as follows.
installing the bolt. for the individual circuits, is located in 1. Turn the key to “OFF” and turn off
the storage compartment. (See page 3- 7
3. Install the panel by installing the the electrical circuit in question.
screw. 8.) 2. Remove the blown fuse, and then
4. Fully charge the battery before in- install a new fuse of the specified 8
stallation. amperage.
9
6-25
5ML-F8199-E2ch6.pmd 25 2005/08/25, 13:17

EAU23710
Specified fuses:
Main fuse:
Replacing a headlight bulb
30 A This model is equipped with quartz bulb
Headlight fuse: headlights. If a headlight bulb burns out, 1
1 15 A replace it as follows.
Signaling system fuse: 1. Place the vehicle on the
2 15 A centerstand.
Ignition fuse: 2. Remove panel B. (See page 6-6.)
7.5 A 3. Disconnect the headlight coupler,
3 Carburetor heater fuse:
and then remove the bulb cover.
7.5 A ZAUM00**
4 ECA10640
1. Headlight bulb holder
EWA10790
cC w
5 Do not use a fuse of a higher amper- Headlight bulbs get very hot. There-
age rating than recommended to 1
fore, keep flammable products away
6 avoid causing extensive damage to from a lit headlight bulb, and do not
the electrical system and possibly a touch the bulb until it has cooled
7 fire. down.
ZAUM00**
3. Turn the key to “ON” and turn on 5. Place a new headlight bulb into po-
8
the electrical circuit in question to 1. Bulb cover sition, and then secure it with the
check if the device operates. 4. Unhook the headlight bulb holder, bulb holder.
9 4. If the fuse immediately blows again, ECA10660
and then remove the defective bulb.
have a Yamaha dealer check the cC
electrical system. Do not touch the glass part of the
headlight bulb to keep it free from oil,
otherwise the transparency of the
glass, the luminosity of the bulb, and
6-26
5ML-F8199-E2ch6.pmd 26 2005/08/25, 13:17

EAU24131 ECA10680
the bulb life will be adversely affected.
Thoroughly clean off any dirt and fin- Replacing the tail/brake light cC
gerprints on the headlight bulb us- bulb Do not overtighten the screws, other-
ing a cloth moistened with alcohol 1. Remove the tail/brake light lens by wise the lens may break.
1
or thinner. removing the screws.
2. Remove the defective bulb by push-
ing it in and turning it counterclock- 2
6. Install the headlight bulb cover, and
then connect the coupler. wise.
7. Install the panel. 3
8. Have a Yamaha dealer adjust the
headlight beam if necessary. 4
ZAUM00**
1
7
1. Bulb
3. Insert a new bulb into the socket, 8

push it in, and then turn it clock-
wise until it stops. 9
4. Install the lens by installing the
screws.
6-27
5ML-F8199-E2ch6.pmd 27 2005/08/25, 13:17

EAUT1360 EAUT1330
5. Insert a new bulb into the socket,
Replacing a front turn signal push it in, and then turn it clock- Rear turn signal light bulb
light bulb wise until it stops. If a rear turn signal light does not come
ECA10670
6. Install the socket (together with the on, have a Yamaha dealer check the
1 cC electrical circuit or replace the bulb.
bulb) by turning it clockwise.
It is advisable to have a Yamaha dealer 7. Install the panel.
2 perform this job.
3 1. Place the scooter on the

centerstand.
4 2. Remove panel A. (See page 6-6.)
3. Remove the socket (together with
the bulb) by turning it counterclock-
5 wise.
4. Remove the defective bulb by push-
6 ing it in and turning it counterclock-
wise.
7
1
8
2
9
ZAUM00**
1. Socket
2. Turn signal light bulb
6-28
5ML-F8199-E2ch6.pmd 28 2005/08/25, 13:17

EAU25860
Troubleshooting
Although Yamaha scooters receive a
thorough inspection before shipment
from the factory, trouble may occur dur- 1
ing operation. Any problem in the fuel,
compression, or ignition systems, for 2
example, can cause poor starting and
loss of power. 3
The following troubleshooting chart rep-
resents a quick and easy procedure for
checking these vital systems yourself. 4
However, should your scooter require any
repair, take it to a Yamaha dealer, whose 5
skilled technicians have the necessary
tools, experience, and know-how to ser- 6
vice the scooter properly.
Use only genuine Yamaha replacement
parts. Imitation parts may look like 7
Yamaha parts, but they are often infe-
rior, have a shorter service life and can 8
lead to expensive repair bills.
9
6-29
5ML-F8199-E2ch6.pmd 29 2005/08/25, 13:17

EAU25901
Troubleshooting chart
EWA10840
w
1 Keep away open flames and do not smoke while checking or working on the fuel system.
2 1. Fuel
There is enough fuel. Check the compression.
Check the fuel level in
3 the fuel tank.
The engine does not start.
There is no fuel. Supply fuel.
Check the compression.
4
2. Compression
There is compression. Check the ignition.
5 Operate the electric starter.
Have a Yamaha dealer
There is no compression.
check the vehicle.
6
3. Ignition 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.
Remove the spark plug
and check the electrodes.
8 The engine does not start.
Dry Have a Yamaha dealer check the vehicle.
Check the battery.
9 4. Battery The engine turns over

The battery is good.
quickly. The engine does not start.
Operate the electric starter. Have a Yamaha dealer
The engine turns over Check the battery lead connections, check the vehicle.
slowly. and charge the battery if necessary.
6-30
5ML-F8199-E2ch6.pmd 30 2005/08/25, 13:17

EAU25990
SCOOTER CARE AND STORAGE

EAU26090
ucts onto seals, gaskets and wheel ucts, solvent or thinner, fuel
Care axles. Always rinse the dirt and (gasoline), rust removers or in-
While the open design of a scooter re- degreaser off with water. hibitors, brake fluid, antifreeze or
veals the attractiveness of the technol- electrolyte.
ogy, it also makes it more vulnerable. 1
Cleaning 8 Do not use high-pressure wash-
Rust and corrosion can develop even if ECA10780
ers or steam-jet cleaners since
high-quality components are used. A cC they cause water seepage and 2
rusty exhaust pipe may go unnoticed on 8 Avoid using strong acidic wheel deterioration in the following ar-
a car, however, it detracts from the over- cleaners, especially on spoked eas: seals (of wheel and 3
all appearance of a scooter. Frequent and wheels. If such products are used swingarm bearings, fork and
proper care does not only comply with on hard-to-remove dirt, do not brakes), electric components
the terms of the warranty, but it will also 4
leave the cleaner on the affected (couplers, connectors, instru-
keep your scooter looking good, extend area any longer than instructed. ments, switches and lights),
its life and optimize its performance. Also, thoroughly rinse the area breather hoses and vents. 5
off with water, immediately dry 8 For scooters equipped with a
Before cleaning it, and then apply a corrosion windshield: Do not use strong 6
1. Cover the muffler outlet with a plas- protection spray. cleaners or hard sponges as they
tic bag after the engine has cooled 8 Improper cleaning can damage will cause dulling or scratching.
down. 7
windshields, cowlings, panels Some cleaning compounds for
2. Make sure that all caps and cov- and other plastic parts. Use only plastic may leave scratches on
ers as well as all electrical couplers a soft, clean cloth or sponge with the windshield. Test the product 8
and connectors, including the spark mild detergent and water to clean on a small hidden part of the
plug cap, are tightly installed. plastic. windshield to make sure that it 9
3. Remove extremely stubborn dirt, 8 Do not use any harsh chemical does not leave any marks. If the
like oil burnt onto the crankcase, products on plastic parts. Be sure windshield is scratched, use a
with a degreasing agent and a to avoid using cloths or sponges quality plastic polishing com-
brush, but never apply such prod- which have been in contact with pound after washing.
strong or abrasive cleaning prod-
7-1
5ML-F8199-E2ch7.pmd 1 2005/07/22, 11:33

ECA10790
After normal use 5. Touch up minor paint damage
Remove dirt with warm water, a mild cC caused by stones, etc.
detergent, and a soft, clean sponge, and Do not use warm water since it in- 6. Wax all painted surfaces.
then rinse thoroughly with clean water. creases the corrosive action of the 7. Let the scooter dry completely be-
1
Use a toothbrush or bottlebrush for hard- salt. fore storing or covering it.
EWA10940
to-reach areas. Stubborn dirt and insects
2 will come off more easily if the area is 2. Apply a corrosion protection spray w
covered with a wet cloth for a few min- on all metal, including chrome- and 8 Make sure that there is no oil or
3 utes before cleaning. nickel-plated, surfaces to prevent wax on the brakes or tires. If nec-
corrosion. essary, clean the brake discs and
After riding in the rain, near the sea or After cleaning brake linings with a regular brake
4
on salt-sprayed roads 1. Dry the scooter with a chamois or disc cleaner or acetone, and
Since sea salt or salt sprayed on the an absorbing cloth. wash the tires with warm water
5 roads during winter are extremely corro- 2. Use a chrome polish to shine and a mild detergent.
sive in combination with water, carry out chrome, aluminum and stainless- 8 Before operating the scooter test
6 the following steps after each ride in the steel parts, including the exhaust its braking performance and cor-
rain, near the sea or on salt-sprayed system. (Even the thermally in- nering behavior.
roads. duced discoloring of stainless-steel
7
exhaust systems can be removed ECA10800
NOTE: through polishing.)

8
Salt sprayed on roads in the winter may 3. To prevent corrosion, it is recom- cC
remain well into spring. mended to apply a corrosion pro- 8 Apply spray oil and wax spar-
9 tection spray on all metal, includ- ingly and make sure to wipe off
ing chrome- and nickel-plated, sur- any excess.
1. Clean the scooter with cold water
faces. 8 Never apply oil or wax to any rub-
and a mild detergent after the en-
4. Use spray oil as a universal cleaner ber and plastic parts, but treat
gine has cooled down.
to remove any remaining dirt. them with a suitable care prod-
uct.
7-2
5ML-F8199-E2ch7.pmd 2 2005/07/22, 11:33

8 Avoid using abrasive polishing EAU26300
3. Fill up the fuel tank and add fuel
compounds as they will wear Storage stabilizer (if available) to prevent the
away the paint. Short-term fuel tank from rusting and the fuel
Always store your scooter in a cool, dry from deteriorating.
place and, if necessary, protect it 1
4. Perform the following steps to pro-
NOTE: against dust with a porous cover. tect the cylinder, piston rings, etc.
Consult a Yamaha dealer for advice on ECA10820
2
from corrosion.
what products to use. cC
a. Remove the spark plug cap and
8 Storing the scooter in a poorly spark plug. 3
ventilated room or covering it b. Pour a teaspoonful of engine oil
with a tarp, while it is still wet, into the spark plug bore.
will allow water and humidity to 4
c. Install the spark plug cap onto
seep in and cause rust. the spark plug, and then place
8 To prevent corrosion, avoid the spark plug on the cylinder 5
damp cellars, stables (because of head so that the electrodes are
the presence of ammonia) and grounded. (This will limit spark- 6
areas where strong chemicals are ing during the next step.)
stored. d. Turn the engine over several 7
times with the starter. (This will
Long-term coat the cylinder wall with oil.)
Before storing your scooter for several e. Remove the spark plug cap from 8
months: the spark plug, and then install
1. Follow all the instructions in the the spark plug and the spark plug 9
“Care” section of this chapter. cap.
2. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
fuel tank.
7-3
5ML-F8199-E2ch7.pmd 3 2005/07/22, 11:33

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
1 NOTE:
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
3 pivoting points of all levers and
pedals as well as of the sidestand/
4 centerstand.
6. Check and, if necessary, correct
the tire air pressure, and then lift
5 the scooter so that both of its
wheels are off the ground. Alterna-
6 tively, turn the wheels a little every
month in order to prevent the tires
7 from becoming degraded in one
spot.
7. Cover the muffler outlet with a plas-
8 tic bag to prevent moisture from en-
tering it.
9 8. Remove the battery and fully charge
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
5ML-F8199-E2ch7.pmd 4 2005/07/22, 11:33

EAU26320
SPECIFICATIONS
Dimensions Engine oil Carburetor
Overall length Type Manufacturer
1855 mm (73.0 in) SAE10W30 or SAE10W40 or SAE15W40 TAIWAN KEIHIN
Overall width or SAE20W40 or SAE20W50 Type x quantity
685 mm (27.0 in) Recommended engine oil grade CVK24 x 1 1
Overall height API service SE, SF, SG type or higher Spark plug (s)
1110 mm (43.7 in) Manufacturer/model
Seat height -20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚ NGK/CR7E 2
770 mm (30.3 in) Spark plug gap
Wheelbase 0.6-0.7 mm (0.024-0.028 in)
1295 mm (51.0 in) SAE 10W-30 Clutch 3
Ground clearance Clutch type
110 mm (4.33 in) SAE 10W-40
Dry, centrifugal automatic
Minimum turning radius SAE 20W-40 Transmission 4
1900 mm (74.8 in) Primary reduction system
Weight SAE 20W-50
Helical gear
With oil and fuel Primary reduction ratio
5
121.0 kg (267 lb) ZAUM00**
38/13 (2.923)
Engine Secondary reduction system
Engine type
6
Engine oil quantity Helical gear
Forced air cooled 4-stroke, SOHC Without oil filter element removal Secondary reduction ratio
Cylinder arrangement 0.90 L (0.95 US qt) (0.79 Imp.qt) 40/12 (3.333)
Forward-inclined single cylinder
7
Final transmission oil Transmission type
Displacement Type V-belt automatic
124.0 cm3 (7.57 cu.in) SAE10W30 type SE motor oil Operation 8
Bore x stroke Quantity Centrifugal automatic type
52.4 x 57.9 mm (2.06 x 2.28 in) 0.11 L (0.12 US qt) (0.10 Imp.qt) Chassis
Compression ratio Air filter Frame type 9
10.00 :1 Air filter element Steel tube backbone
Starting system Oil-coated paper element Caster angle
Electric starter and kickstarter 27.00°
Fuel
Lubrication system Trail
Recommended fuel
Wet sump 90.0 mm (3.54 in)
Regular unleaded gasoline only
Fuel tank capacity
7.1 L (1.88 US gal) (1.56 Imp.gal)
8-1
5ML-F8199-E2ch8rev.pmd 1 2005/08/25, 13:31

SPECIFICATIONS
Front tire Rear wheel Electrical system
Type Wheel type Ignition system
Tubeless Cast wheel CDI
Size Rim size Charging system
1 110/70-12 47L 12 x MT3.00 AC magneto
Manufacturer/model Front brake Battery
CHENG SHIN/C-922N-47L Type Model
2 Rear tire Single disc brake YTX7A-BS
Type Operation Voltage, capacity
Tubeless Right hand operation 12 V, 6.0 Ah
3 Size Recommended fluid Headlight
120/70-12 58L DOT 4 Bulb type
Manufacturer/model Rear brake Halogen bulb
4 CHENG SHIN/C-6007-58L Type Bulb voltage, wattage x quantity
Loading Drum brake Headlight
Maximum load Operation 12 V, 60 W/55.0 W x 1
5 170 kg (375 lb) Left hand operation Tail/brake light
Tire air pressure (measured on cold tires) Front suspension 12 V, 5.0 W/21.0 W x 1
Loading condition Type Front turn signal light
6 0-90 kg (0-198 lb) Telescopic fork 12 V, 10.0 W x 2
Front Spring/shock absorber type Rear turn signal light
175 kPa (25 psi) (1.75 kgf/cm2) Coil spring/oil damper 12 V, 16.0 W x 2
7
Rear Wheel travel Auxiliary light
200 kPa (29 psi) (2.00 kgf/cm2) 90.0 mm (3.54 in) 12 V, 5.0 W x 1
8 Loading condition Rear suspension Meter lighting
90-170 kg (198-375 lb) Type 12 V, 1.7 W x 3
Front Unit swing High beam indicator light
9 200 kPa (29 psi) (2.00 kgf/cm2) Spring/shock absorber type 12 V, 1.7 W x 1
Rear Coil spring/oil damper Turn signal indicator light
225 kPa (33 psi) (2.25 kgf/cm2) Wheel travel 12 V, 3.4 W x 1
Front wheel 95.0 mm (3.74 in)
Wheel type
Cast wheel
Rim size
12 x MT2.75
8-2
5ML-F8199-E2ch8rev.pmd 2 2005/08/25, 13:31

SPECIFICATIONS
Fuses
Main fuse
30.0 A
Headlight fuse
15.0 A 1
Signaling system fuse
15.0 A
Ignition fuse 2
7.5 A
Carburetor heater fuse
7.5 A 3
8-3
5ML-F8199-E2ch8rev.pmd 3 2005/08/25, 13:31

CONSUMER INFORMATION
EAU26351 EAU26381 EAU26410
Identification numbers Key identification number Vehicle identification number

Record the key identification number,
vehicle identification number and model 1
1 1
label information in the spaces provided
below for assistance when ordering
2 spare parts from a Yamaha dealer or for
reference in case the vehicle is stolen.
3
KEY IDENTIFICATION NUMBER:
4 ZAUM00**
ZAUM00**
1. Key identification number 1. Vehicle identification number

5
The key identification number is The vehicle identification number is
VEHICLE IDENTIFICATION NUMBER: stamped into the key tag. 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
used to register your motorcycle with
8 MODEL LABEL INFORMATION: the licensing authority in your area.
9-1
5ML-F8199-E2ch9.pmd 1 2005/07/22, 11:34

CONSUMER INFORMATION
EAUT1440
Model label
1
1
2
ZAUM00** 4
1. Model label
5
The model label is affixed to the inside
of the storage compartment. (See page
6
3-8.) Record the information on this la-
bel in the space provided. This informa-
tion will be needed when ordering spare 7
parts from a Yamaha dealer.
8
9-2
5ML-F8199-E2ch9.pmd 2 2005/07/22, 11:34

INDEX
A H Spark plug, checking ................................ 6-7
Acceleration and deceleration .................. 5-2 Handlebar switches .................................. 3-3 Specifications ............................................ 8-1
Air filter and V-belt case air filter Headlight bulb, replacing ........................ 6-26 Speedometer unit ..................................... 3-3
elements ................................................ 6-11 Helmet holder ............................................ 3-8 Start switch ............................................... 3-4
1 B High beam indicator light .......................... 3-2 Starting a cold engine ............................... 5-1
Battery ..................................................... 6-23 Horn switch ............................................... 3-4 Starting off ................................................. 5-2
Brake fluid level, checking ...................... 6-19 I Storage ...................................................... 7-3
2 Brake fluid, changing .............................. 6-20 Identification numbers .............................. 9-1 Storage compartment ............................... 3-8
Brake lever, front ...................................... 3-4 Indicator lights ........................................... 3-2 T
Brake lever, rear ....................................... 3-4 K Tail/brake light bulb, replacing ................ 6-27
3 Brake levers, lubricating ......................... 6-21 Key identification number ......................... 9-1 Throttle cable free play, adjusting .......... 6-14
Brake pads and shoes, checking .......... 6-18 Kickstarter ................................................ 3-7 Throttle grip and cable, checking and lubricat-
Braking ...................................................... 5-2 L ing .......................................................... 6-21
4 Tires ........................................................ 6-15
C Luggage hook ........................................... 3-9
Cables, checking and lubricating ........... 6-20 M Tool kit ....................................................... 6-1
5 Carburetor,adjusting ............................... 6-13 Troubleshooting ...................................... 6-29
Main switch/steering lock ......................... 3-1
Catalytic converter ................................... 3-6 Model label ................................................ 9-2 Troubleshooting chart ............................. 6-30
Centerstand and sidestand, checking and lu- Turn signal indicator light .......................... 3-2
P
6 bricating ................................................. 6-21 Turn signal light bulb (front), replacing ... 6-28
Panels, removing and installing ................ 6-6
D Turn signal switch ..................................... 3-4
Parking ...................................................... 5-4
Dimmer switch .......................................... 3-4 Part locations ............................................ 2-1
V
7 E Valve clearance ...................................... 6-14
Periodic maintenance and lubrication
Engine break-in ......................................... 5-3 chart ........................................................ 6-3 Vehicle identification number .................... 9-1
Engine oil and oil strainer .......................... 6-8 Pre-operation check list ........................... 4-2 W
8 Wheel bearings, checking ...................... 6-23
F Rear brake lever free play, adjusting ..... 6-18
Final transmission oil .............................. 6-10 S Wheels .................................................... 6-17
9 Front brake lever free play, checking .... 6-17 Safe-riding points ...................................... 1-4
Fuel ........................................................... 3-6 Safety information ..................................... 1-1
Fuel consumption, tips for reducing ......... 5-3 Seat ........................................................... 3-7
Fuel gauge ................................................ 3-3 Sidestand ................................................ 3-10
Fuel tank cap ............................................ 3-5 Sidestand switch operation check ......... 3-10
Fuses, replacing ..................................... 6-25
5ML-F8199-E2idx.pmd 1 2005/07/22, 11:34

1
5ML-F819U-E2ch0.pmd 1 2005/07/22, 11:27

1
YAMAHA MOTOR TAIWAN CO.,LTD

PRINTED IN TAIWAN
2005・9−0.3×1 !
(E)
5ML-F8199-E2cv.pmd 2 2005/08/01, 10:04

5ml f8199 E2

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

5ml f8199 E2

Uploaded by

Copyright:

Available Formats

1

5ML-F8199-E2cv.pmd 3 2005/08/01, 10:04

5ML-F8199-E2ch0.pmd 1 2005/07/22, 11:31

5ML-F8199-E2ch0.pmd 2 2005/07/22, 11:31

IMPORTANT MANUAL INFORMATION

*Product and specifications are subject to change without notice.

5ML-F8199-E2ch0.pmd 3 2005/07/22, 11:31

5ML-F8199-E2ch0.pmd 4 2005/07/22, 11:31

5ML-F8199-E2ch0.pmd 5 2005/07/22, 11:31

5ML-F8199-E2ch0.pmd 6 2005/07/22, 11:31

5ML-F8199-E2ch1.pmd 1 2005/08/25, 13:16

5ML-F8199-E2ch1.pmd 2 2005/08/25, 13:16

5ML-F8199-E2ch1.pmd 3 2005/08/25, 13:16

9 The engine and exhaust

5ML-F8199-E2ch1.pmd 4 2005/08/25, 13:16

5ML-F8199-E2ch1.pmd 5 2005/08/25, 13:16

5ML-F8199-E2ch1.pmd 6 2005/08/25, 13:16

5ML-F8199-E2ch2.pmd 1 2005/07/22, 11:32

1. Front turn signal light(Page6-28)

5ML-F8199-E2ch2.pmd 2 2005/07/22, 11:32

Controls and instruments

9 1.Rear brake lever (Page3-4)

5ML-F8199-E2ch2.pmd 3 2005/07/22, 11:32

INSTRUMENT AND CONTROL FUNCTIONS

5ML-F8199-E2ch3.pmd 1 2005/08/25, 13:17

5 1. High beam indicator light ”&”

5ML-F8199-E2ch3.pmd 2 2005/08/25, 13:17

Speedometer unit Fuel gauge Handlebar switches

1. Speedometer 1. Dimmer switch “%/&“

1. Start switch “,”

5ML-F8199-E2ch3.pmd 3 2005/08/25, 13:17

5ML-F8199-E2ch3.pmd 4 2005/08/25, 13:17

1. Fuel tank cap

5ML-F8199-E2ch3.pmd 5 2005/08/25, 13:17

5ML-F8199-E2ch3.pmd 6 2005/08/25, 13:17

Kickstarter Seat NOTE:

To start the engine, fold out the 5

and then push it down smoothly but

5ML-F8199-E2ch3.pmd 7 2005/08/25, 13:17

1. Helmet holder 1. Storage compartment

may hit objects, causing loss of con- cC

5ML-F8199-E2ch3.pmd 8 2005/08/25, 13:17

5ML-F8199-E2ch3.pmd 9 2005/08/25, 13:17

5ML-F8199-E2ch3.pmd 10 2005/08/25, 13:17

Turn the key on.

Put the sidestand up. 1

Push the start switch while applying 2

Put the sidestand down. 4

5ML-F8199-E2ch3.pmd 11 2005/08/25, 13:17

5ML-F8199-E2ch4.pmd 1 2005/07/22, 11:32

Pre-operation check list

5ML-F8199-E2ch4.pmd 2 2005/07/22, 11:32

5ML-F8199-E2ch4.pmd 3 2005/07/22, 11:32

OPERATION AND IMPORTANT RIDING POINTS

5ML-F8199-E2ch5.pmd 1 2005/07/22, 11:32

Starting off Acceleration and deceleration Braking

5ML-F8199-E2ch5.pmd 2 2005/07/22, 11:32

5ML-F8199-E2ch5.pmd 3 2005/07/22, 11:32

5ML-F8199-E2ch5.pmd 4 2005/07/22, 11:32

PERIODIC MAINTENANCE AND MINOR REPAIR

5ML-F8199-E2ch6.pmd 1 2005/08/25, 13:17

5ML-F8199-E2ch6.pmd 2 2005/08/25, 13:17

Periodic maintenance and lubrication chart