Professional Documents
Culture Documents
EAU04576
INTRODUCTION
As the owner of the YP250, you are benefiting from Yamaha’s vast experience and newest technolo-
gy regarding the design and manufacture of high-quality products, which have earned Yamaha a rep-
utation for dependability.
Please take the time to read this manual thoroughly, so as to enjoy all advantages of your YP250.
The owner’s manual 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.
In addition, the many tips given in this manual will help keep your scooter in the best possible condi-
tion. If you have any further questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!
5SJ-28199-E2 8/9/02 4:05 PM Page 2
EAU00005
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
Q IS INVOLVED!
NOTE:
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 current product information available at the time of printing, there
may be minor discrepancies between your scooter and this manual. If you have any ques-
tions concerning this manual, please consult your Yamaha dealer.
5SJ-28199-E2 8/9/02 4:05 PM Page 3
w
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING
THIS SCOOTER.
5SJ-28199-E2 8/9/02 4:05 PM Page 4
EAU04229
YP250
OWNER’S MANUAL
©2002 by Yamaha Motor Co., Ltd.
1st edition, July 2002
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
5SJ-28199-E2 8/9/02 4:05 PM Page 5
EAU00009
TABLE OF CONTENTS
2 DESCRIPTION 2
4 PRE-OPERATION CHECKS 4
8 SPECIFICATIONS 8
9 CONSUMER INFORMATION 9
INDEX
5SJ-28199-E2 8/9/02 4:05 PM Page 6
5SJ-28199-E2 8/9/02 4:05 PM Page 7
EAU00021
Protective clothing is as essential for the scooter rider as seat belts are for car drivers and passen-
gers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic
materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum pro-
tective wear, however, should not encourage carelessness. Although full-coverage helmets and suits,
in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable.
Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is
even more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensive-
ly—avoiding all dangers, including those caused by others.
1-1
5SJ-28199-E2 8/9/02 4:05 PM Page 9
1-2
5SJ-28199-E2 8/9/02 4:05 PM Page 10
5SJ-28199-E2 8/9/02 4:05 PM Page 11
DESCRIPTION
EAU00026
Left view
1 2
8 7 6 5 4 3
1. Rear storage compartment (page 3-18) 5. V-belt case air filter element (page 6-22)
2. Grab bar (page 5-2) 6. Centerstand (page 6-31)
3. Shock absorber spring preload 7. Sidestand (page 3-20, 6-31)
adjusting ring (page 3-19) 8. Fuel tank cap (page 3-13)
4. Air filter element (page 6-21)
2-1
5SJ-28199-E2 8/9/02 4:05 PM Page 13
DESCRIPTION
Right view 9 10
11 2
12
18 17 16 15 14 13
9. Passenger seat 14. Battery (page 6-34)
10. Rider seat (page 3-17) 15. Fuse box (page 6-36)
11. Air flow louver (page 6-23) 16. Coolant reservoir cap (page 6-19)
12. Headlight (page 6-37) 17. Coolant level check window (page 6-19)
13. Radiator 18. Engine oil filler cap (page 6-15)
2-2
5SJ-28199-E2 8/9/02 4:05 PM Page 14
DESCRIPTION
Controls and instruments
1 2 34 5 6 7 8 9 10
13 12 11
1. Rear brake lever (page 3-13) 8. Fuel gauge (page 3-4)
2. Left handlebar switches (page 3-10) 9. Right handlebar switches (page 3-12)
3. Front storage compartment A (page 3-17) 10. Front brake lever (page 3-12)
4. Coolant temperature gauge (page 3-5) 11. Throttle grip (page 6-23, 6-31)
5. Tachometer (page 3-3) 12. Front storage compartment B (page 3-18)
6. Speedometer (page 3-3) 13. Main switch/steering lock (page 3-1)
7. Multi-function display (page 3-5)
2-3
5SJ-28199-E2 8/9/02 4:05 PM Page 15
EAU00027
w
EAU00040
trols the ignition and lighting systems,
LOCK
and is used to lock the steering. The Never turn the key to “OFF” or
The steering is locked, and all electri-
various positions are described “LOCK” while the scooter is mov-
cal systems are off. The key can be
below. ing, otherwise the electrical sys-
removed.
tems will be switched off, which
EAU04580
may result in loss of control or an
ON
accident. Make sure that the scoot-
All electrical circuits are supplied with
er is stopped before turning the
power; the meter lighting, taillight,
key to “OFF” or “LOCK”.
license plate light and auxiliary light
come on, and the engine can be
started. The key cannot be removed.
3-1
5SJ-28199-E2 8/9/02 4:05 PM Page 17
. (Parking) 1 2 3 4 Oil change indicator light “7” Oil change indicator light
The steering is locked, and the tail- This indicator light comes on at the
light, license light and auxiliary light initial 1,000 km and every 3,000 km
are on, but all other electrical sys- thereafter to indicate that the engine
tems are off. The key can be oil should be changed.
removed. If the engine oil is changed before the
oil change indicator comes on (i.e. 3
To turn the main switch to “.”: before the periodic oil change interval
1. Turn the key to “LOCK”. 1. Left turn signal indicator light “4” has been reached), the indicator light
2. High beam indicator light “&”
2. Slightly turn the key counter- 3. Oil change indicator light “7”
must be reset after the oil change for
clockwise until it stops. 4. Right turn signal indicator light “6” the next periodic oil change to be
3. While still turning the key coun- EAU00056 indicated at the correct time. (See
terclockwise, push it in until it Indicator lights Indicator lights
goes off.
This indicator light comes on when
3. If the indicator light does not
the high beam of the headlight is
come on, have a Yamaha dealer
switched on.
check the electrical circuit.
3-2
5SJ-28199-E2 8/9/02 4:05 PM Page 18
NOTE: 1 1
The oil change indicator light may
flash when the engine is revved with
the scooter on the centerstand, but
this does not indicate a malfunction.
1. Speedometer 1. Tachometer
EAU04581 EAU04582
The speedometer shows the riding The electric tachometer allows the
speed. rider to monitor the engine speed and
When the key is turned to “ON”, the keep it within the ideal power range.
speedometer needle will move to When the key is turned to “ON”, the
160 km/h and back to zero in order to tachometer needle will move to the
test the electrical circuit. 10,000 r/min and back to zero r/min
in order to test the electrical circuit.
3-3
5SJ-28199-E2 8/9/02 4:05 PM Page 19
cC
1
8 Do not operate the engine
above 8,500 r/min.
8 This scooter is equipped with
an engine speed limiter, which
prevents the engine speed
from exceeding approximately 3
9,000 r/min.
1. Fuel gauge
EAU00110
NOTE:
Do not allow the fuel tank to empty
itself completely.
3-4
5SJ-28199-E2 8/9/02 4:05 PM Page 20
2 2
1
3 1 2
perature when the main switch is on. The multi-function display is NOTE:
The engine operating temperature equipped with the following: 8 When the key is turned to “ON”,
will vary with changes in weather and 8 a tripmeter (which shows the dis- all segments of the display come
engine load. If the needle points to tance traveled since it was last on for a few seconds. During this
the red mark, stop your scooter and set to zero) time, the multi-function display is
let the engine cool. (See page 6-44 8 a fuel tripmeter (which shows the performing a self-test.
for details.) distance traveled when the fuel 8 Be sure to turn the key to “ON”
EC000002
level reaches approximately before using the “SELECT” and
cC
2.0 L) “RESET” buttons.
Do not operate the engine if it is 8 an odometer (which shows the
overheated. total distance traveled)
8 a clock
8 an outside temperature display
3-5
5SJ-28199-E2 8/9/02 4:05 PM Page 21
NOTE:
8 The tripmeter reset mode auto-
matically cancels after five sec-
onds. To return to the reset
mode, push the “SELECT” but-
ton again until “Trip” begins
flashing.
3
8 To cancel the tripmeter reset
mode, push the “SELECT” but-
ton.
Tripmeter “Trip” Odometer “Odo”
8 If the tripmeter indicates “– – – –”,
To reset the tripmeter: The odometer has two functions.
have a Yamaha dealer check or
1. Push the “SELECT” button until 8 It shows the total distance trav-
repair the multi-function display
the voltage display appears, then eled.
as it may be faulty.
push the “SELECT” button one 8 It automatically changes to the
more time and “Trip” starts flash- fuel tripmeter mode “Trip F”
ing. when the fuel level reaches
2. Push the “RESET” button for at approximately 2.0 L. (See “Fuel
least one second to reset the tripmeter” for details.)
tripmeter to zero.
NOTE:
If the odometer indicates “– – – – – – ”,
have a Yamaha dealer check or
repair the multi-function display as it
may be faulty.
3-6
5SJ-28199-E2 8/9/02 4:05 PM Page 22
NOTE:
The display cannot be changed back
to “Trip F” after pushing the “RESET”
button.
3-7
5SJ-28199-E2 8/9/02 4:05 PM Page 23
3. When the hour digits start flash- 4. Push the “SELECT” button, and Outside temperature display
ing, push the “RESET” button to the minute digits will start flash- This display shows the outside tem-
set the hours. ing. perature from -10.0 °C to 50.0 °C in
5. Push the “RESET” button to set 0.5 °C increments.
the minutes.
6. Push the “SELECT” button and
then release it to start the clock.
3-8
5SJ-28199-E2 8/9/02 4:05 PM Page 24
falls below -10.0 °C, “– – °C “ is Anti-theft alarm (optional) Anti-theft alarm (optional)
3 NOTE:
8 If “– – °C” is displayed or “50.0”
flashes while the outside temper-
ature is between -10.0 °C and Voltage display
50.0 °C, there is a problem with This display shows the battery volt-
the electrical circuit. Have a age.
Yamaha dealer check or repair ECA00135
3-9
5SJ-28199-E2 8/9/02 4:05 PM Page 25
EAU00120
EAU03888
3-10
5SJ-28199-E2 8/9/02 4:05 PM Page 26
NOTE:
Right and left are defined as seen when standing in front of the scooter.
3-11
5SJ-28199-E2 8/9/02 4:05 PM Page 27
2
cC
3
See page 5-1 for starting instruc-
1. Engine stop switch “#/$” tions prior to starting the engine. 1. Front brake lever
2. Start switch “,”
EAU03882
EAU03890
Front brake lever Brake lever, front
3-12
5SJ-28199-E2 8/9/02 4:05 PM Page 28
1
1 1
2
3
The rear brake lever is located on the released and the fuel tank cap
left handlebar grip. To apply the rear
Fuel tank cap
3-13
5SJ-28199-E2 8/9/02 4:05 PM Page 29
cC
Immediately wipe off spilled fuel
1 with a clean, dry, soft cloth, since
fuel may deteriorate painted sur-
faces or plastic parts.
2
1
3
fuel tank cap into the tank open- Make sure that there is sufficient fuel
ing, and then push down on the in the tank. Fill the fuel tank to the
cap. bottom of the filler tube as shown.
2. Turn the key counterclockwise to EW000130
3-14
5SJ-28199-E2 8/9/02 4:05 PM Page 30
3-15
5SJ-28199-E2 8/9/02 4:05 PM Page 31
cC a
ON 1
The following precautions must be OFF
observed to prevent a fire hazard OPEN
N
PUSH
The use of leaded gasoline will
O
P TI
I G NI
cause unrepairable damage to 3
the catalytic converter.
8 Never park the scooter near a. Open. 1. Rider seat
3-16
5SJ-28199-E2 8/9/02 4:05 PM Page 32
1
3 1 1 2
1. Rider seat 1. Bolt (×4) 1. Button
2. Collar (×4) 2. Lid
EAU03096
a. Open.
Adjusting the rider seat Rider seat, adjusting
2. Remove the bolts and collars. EAU03331
The rider seat can be adjusted as fol- 3. Slide the rider seat forward or Storage compartments Storage compartments
3-17
5SJ-28199-E2 8/9/02 4:05 PM Page 33
a
1
1 2
2 3
w
Do not store heavy items in this
compartment.
3-18
5SJ-28199-E2 8/9/02 4:05 PM Page 34
cC
3
EWA00035 Never attempt to turn an adjusting
w mechanism beyond the maximum 1. Spring preload adjusting ring
2. Position indicator
Do not exceed the following load- or minimum settings. 3. Spring preload adjusting tool
ing limits: Adjust the spring preload as follows.
EW000040
8 Front storage compartment A:
w To increase the spring preload and
2 kg thereby harden the suspension, turn
8 Rear storage compartment: Always adjust both shock
the adjusting ring on each shock
5 kg absorber assemblies equally, oth-
absorber assembly in direction a. To
8 Maximum load for the vehicle: erwise poor handling and loss of
decrease the spring preload and
185 kg stability may result.
thereby soften the suspension, turn
the adjusting ring on each shock
absorber assembly in direction b.
3-19
5SJ-28199-E2 8/9/02 4:05 PM Page 35
NOTE: 1 w
8 Align the appropriate notch in the The scooter must not be ridden
adjusting ring with the position with the sidestand down, or if the
indicator on the shock absorber. sidestand cannot be properly
8 Use the spring preload adjusting moved up (or does not stay up),
tool included in the owner’s tool otherwise the sidestand could con-
kit to make this adjustment. tact the ground and distract the 3
operator, resulting in a possible
1. Sidestand switch loss of control. Yamaha’s ignition
Setting
Minimum (soft) 1 EAU00330 circuit cut-off system has been
Standard 4 Sidestand Sidestand
3-20
5SJ-28199-E2 8/9/02 4:05 PM Page 36
w
If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
3-21
5SJ-28199-E2 8/9/02 4:05 PM Page 37
3-22
5SJ-28199-E2 8/9/02 4:05 PM Page 38
5SJ-28199-E2 8/9/02 4:05 PM Page 39
PRE-OPERATION CHECKS
4
5SJ-28199-E2 8/9/02 4:05 PM Page 40
EAU01114
PRE-OPERATION CHECKS
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
EAU03439
4-1
5SJ-28199-E2 8/9/02 4:05 PM Page 41
PRE-OPERATION CHECKS
ITEM CHECKS PAGE
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
Rear brake • Check fluid level in reservoir. 3-13, 6-27–6-30
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Make sure that operation is smooth.
• Check cable free play.
Throttle grip 6-23, 6-31
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.
• Check for damage.
• Check tire condition and tread depth.
Wheels and tires 6-24–6-27
• Check air pressure. 4
• Correct if necessary.
• Make sure that operation is smooth.
Brake levers 3-12–3-13, 6-27, 6-31
• Lubricate lever pivoting points if necessary.
• Make sure that operation is smooth.
Centerstand, sidestand 6-31–6-32
• Lubricate pivots if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
Chassis fasteners —
• Tighten if necessary.
Instruments, lights, signals • Check operation.
3-2–3-12, 6-37–6-42
and switches • Correct if necessary.
• Check operation of ignition circuit cut-off system.
Sidestand switch 3-20–3-22
• If system is defective, have Yamaha dealer check vehicle.
4-2
5SJ-28199-E2 8/9/02 4:05 PM Page 42
PRE-OPERATION CHECKS
NOTE:
Pre-operation checks should be made each time the scooter 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.
EWA00033
w
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operat-
ing the scooter.
4-3
5SJ-28199-E2 8/9/02 4:05 PM Page 43
5
5SJ-28199-E2 8/9/02 4:05 PM Page 44
EAU00372
EC000046 2
8 Become thoroughly familiar cC
with all operating controls and See page 5-4 for engine break-in
their functions before riding. instructions prior to operating the
Consult a Yamaha dealer vehicle for the first time.
regarding any control or func-
1
tion that you do not thorough- In order for the ignition circuit cut-off
ly understand. system to enable starting, the side- 1. Start switch
2. Front brake lever
8 Never start the engine or oper- stand must be up. 3. Rear brake lever
ate it in a closed area for any EW000054
5 length of time. Exhaust fumes w 1. Turn the key to “ON” and make
are poisonous, and inhaling sure that the engine stop switch
8 Before starting the engine,
them can cause loss of con- is set to “#”.
check the function of the igni-
sciousness and death within a 2. Close the throttle completely.
tion circuit cut-off system
short time. Always make sure 3. Start the engine by pushing the
according to the procedure
that there is adequate ventila- start switch while applying the
described on page 3-22.
tion. front or rear brake.
8 Never ride with the sidestand
8 For safety, always start the down.
engine with the centerstand
down.
5-1
5SJ-28199-E2 8/9/02 4:05 PM Page 45
Starting off
ECA00045 5
cC
Starting off
NOTE:
For maximum engine life, never Before starting off, allow the engine
accelerate hard when the engine is to warm up.
cold!
1. While pulling the rear brake lever
with your left hand and holding
the grab bar with your right hand,
push the scooter off the center-
stand.
2. Sit astride the seat, and then
adjust the rear view mirrors.
3. Switch the turn signal on.
5-2
5SJ-28199-E2 8/9/02 4:05 PM Page 46
w
8 Avoid braking hard or sudden-
b ly (especially when leaning
over to one side), otherwise
the scooter may skid or over-
a turn.
8 Railroad crossings, streetcar
rails, iron plates on road con-
struction sites, and manhole
EAU00434 EAU00435 covers become extremely slip-
Acceleration and Braking Braking
5-3
5SJ-28199-E2 8/9/02 4:05 PM Page 47
cC
8 Keep the engine speed below
8,500 r/min.
8 If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the vehi-
cle.
5-4
5SJ-28199-E2 8/9/02 4:05 PM Page 48
Parking Parking
w
8 Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely
to touch them.
5 8 Do not park on a slope or on
soft ground, otherwise the
scooter may overturn.
EC000062
cC
Never park in an area where there
are fire hazards such as grass or
other flammable materials.
5-5
5SJ-28199-E2 8/9/02 4:05 PM Page 49
EAU00462
Periodic inspection, adjustment and If you are not familiar with scooter The owner’s tool kit is located inside
lubrication will keep your vehicle in maintenance work, have a Yamaha the rear storage compartment. (See
the safest and most efficient condi- dealer do it for you. page 3-18 for the rear storage com-
tion possible. The most important partment opening procedures.)
points of inspection, adjustment, and EAU00466
6-1
5SJ-28199-E2 8/9/02 4:05 PM Page 51
1 NOTE:
If you do not have the tools or experi-
ence required for a particular job,
have a Yamaha dealer perform it for
you.
2
EW000063
w
1. Mat Modifications not approved by
2. Owner’s tool kit Yamaha may cause loss of perfor-
Pull up the mat, and then remove the mance and render the vehicle
owner’s tool kit. unsafe for use. Consult a Yamaha
The service information included in dealer before attempting any
this manual and the tools provided in changes. 6
the owner’s tool kit are intended to
assist you in the performance of pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be nec-
essary to perform certain mainte-
nance work correctly.
6-2
5SJ-28199-E2 8/9/02 4:05 PM Page 52
Periodic maintenance and lubrication chart Periodic maintenance and lubrication chart
NOTE:
8 The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8 From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
8 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
6-3
5SJ-28199-E2 8/9/02 4:05 PM Page 53
6-4
5SJ-28199-E2 8/9/02 4:05 PM Page 54
EAU03884
NOTE:
8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
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 cylinders and calipers, and change the
brake fluid.
9 Replace the brake hoses every four years and if cracked or damaged.
6-5
5SJ-28199-E2 8/9/02 4:05 PM Page 55
1 1
1. Cowling A 1. Cowling B 1. Cowling C
EAU03624
6-6
5SJ-28199-E2 8/9/02 4:05 PM Page 56
1
1
1
1
2 2
1. Panel A 1. Mat A 1. Screw (×4)
2. Mat B 2. Cowling A
EAU03615
2. Remove the cowling screws.
Cowling A Cowling *
6-7
5SJ-28199-E2 8/9/02 4:05 PM Page 57
1 2
and then pull it outward as 1. Insert the tabs on the cowling Cowling B Cowling *
shown. into the slots as shown, and then To remove the cowling
install the screws. 1. Pull up the right floorboard mats 6
2. Place the floorboard mats in the as shown.
original position.
ECA00067
cC
Take care not to damage the tabs
on the cowling when removing and
or installing it.
6-8
5SJ-28199-E2 8/9/02 4:05 PM Page 58
1 1
2
1. Screw (×4) 1. Tab (×10)
2. Cowling B
3. Pull the cowling down slightly, To install the cowling
2. Remove the screws.
and then pull it outward as 1. Insert the tabs on the cowling
shown. into the slots as shown, and then
install the screws.
6
2. Place the floorboard mats in the
original position.
ECA00067
cC
Take care not to damage the tabs
on the cowling when removing and
or installing it.
6-9
5SJ-28199-E2 8/9/02 4:05 PM Page 59
a a
6-10
5SJ-28199-E2 8/9/02 4:06 PM Page 60
1
1
2 2
6-11
5SJ-28199-E2 8/9/02 4:06 PM Page 61
1
The spark plug is an important
engine component, which is easy to
check. Since heat and deposits will
cause any spark plug to slowly erode,
the spark plug should be removed
and checked in accordance with the
periodic maintenance and lubrication
1. Tab (×4) chart. In addition, the condition of the 1. Spark plug cap
spark plug can reveal the condition of
To install the panel To remove the spark plug
the engine.
Place the panel in the original posi- 1. Remove cowling B. (See page
tion, and then install the bolts. 6-8 for cowling removal and
installation procedures.)
6
2. Remove the spark plug cap.
6-12
5SJ-28199-E2 8/9/02 4:06 PM Page 62
3. Remove the spark plug as defective. Do not attempt to diagnose To install the spark plug
shown, with the spark plug such problems yourself. Instead, 1. Measure the spark plug gap with
wrench included in the owner’s have a Yamaha dealer check the a wire thickness gauge and, if
tool kit. scooter. necessary, adjust the gap to
6
specification.
2. Check the spark plug for elec-
Spark plug gap:
trode erosion and excessive car-
0.6–0.7 mm
bon or other deposits, and
replace it if necessary. 2. Clean the surface of the spark
plug gasket and its mating sur-
Specified spark plug:
face, and then wipe off any grime
DR8EA (NGK)
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
6-13
5SJ-28199-E2 8/9/02 4:06 PM Page 63
6-14
5SJ-28199-E2 8/9/02 4:06 PM Page 64
6-15
5SJ-28199-E2 8/9/02 4:06 PM Page 65
6-16
5SJ-28199-E2 8/9/02 4:06 PM Page 66
NOTE:
If the engine oil is changed before the
1 oil change indicator light comes on
(i.e. before the periodic oil change
interval has been reached), the indi-
cator light must be reset after the oil
change for the next periodic oil
change to be indicated at the correct
1. Reset button time. To reset the oil change indicator
light before the periodic oil change
To reset the oil change indicator 2. Hold the reset button pushed for
interval has been reached, follow the
light two to five seconds.
above procedure, but note that the
1. Turn the key to “ON”. 3. Release the reset button, and
indicator light will come on for
the oil change indicator light will
6 1.4 seconds after releasing the reset
go off.
button, otherwise repeat the proce-
dure.
6-17
5SJ-28199-E2 8/9/02 4:06 PM Page 67
1
The final transmission case must be
checked for oil leakage before each 1
ride. If any leakage is found, have a
Yamaha dealer check and repair the
scooter. In addition, the final trans-
mission oil must be changed as fol-
lows at the intervals specified in the
periodic maintenance and lubrication 1. Final transmission oil filler cap 1. Final transmission oil drain bolt
chart.
4. Remove the oil filler cap and Recommended final transmission
1. Start the engine, warm it up by
drain bolt to drain the oil from the oil:
riding the scooter for several
final transmission case. See page 8-2.
minutes, and then stop the
5. Install the final transmission oil Oil quantity:
engine. 6
drain bolt, and then tighten it to 0.25 L
2. Place the scooter on the center-
the specified torque.
stand. EWA00062
6-18
5SJ-28199-E2 8/9/02 4:06 PM Page 68
6-19
5SJ-28199-E2 8/9/02 4:06 PM Page 69
1 cC NOTE:
8 If coolant is not available, use The radiator fan is automatically
distilled water or soft tap water switched on or off according to the
instead. Do not use hard water coolant temperature in the radiator. If
or salt water since it is harmful the engine overheats, see page 6-44
to the engine. for further instructions.
8 If water has been used instead
of coolant, replace it with
1. Coolant reservoir cap coolant as soon as possible,
3. If the coolant is at or below the otherwise the engine may not
minimum level mark, remove the be sufficiently cooled and the
reservoir cap, add coolant to the cooling system will not be pro-
maximum level mark, and then tected against frost and corro-
sion. 6
install the reservoir cap.
8 If water has been added to the
Coolant reservoir capacity coolant, have a Yamaha dealer
(up to the maximum level mark): check the antifreeze content of
0.4 L the coolant as soon as possi-
4. Install the battery cover. ble, otherwise the effective-
ness of the coolant will be
reduced.
6-20
5SJ-28199-E2 8/9/02 4:06 PM Page 70
1
The air filter and V-belt case air filter
elements should be cleaned at the
intervals specified in the periodic
maintenance and lubrication chart.
Clean both filter elements more fre-
2 3 4
quently if you are riding in unusually
wet or dusty areas. 1. Air filter case cover
EC000092 2. Screw (×5)
cC 3.
4.
Sponge material
Mesh sheet
4. Check the sponge material for
damage and replace it if neces-
8 Make sure that each filter ele- Cleaning the air filter element sary.
ment is properly seated in its 1. Place the scooter on the center- 5. Allow the sponge material to dry.
6 case. stand. 6. Apply oil of the recommended
8 The engine should never be 2. Remove the air filter case cover type to the entire surface of the
operated without the filter ele- by removing the screws. sponge material, and then
ments installed, otherwise the 3. Pull the sponge material out squeeze the excess oil out.
piston and/or cylinder may along with the mesh sheet, clean
become excessively worn. it with solvent, and then squeeze
the remaining solvent out.
6-21
5SJ-28199-E2 8/9/02 4:06 PM Page 71
NOTE: 1 2
The sponge material should be wet
but not dripping.
Recommended oil: 1
2
Engine oil
6-22
5SJ-28199-E2 8/9/02 4:06 PM Page 72
Opening the air flow louver may help The throttle cable free play should
6 reduce air turbulence. measure 3–5 mm at the throttle grip.
Periodically check the throttle cable
To open the air flow louver free play and, if necessary, have a
Move the lever in direction a. Yamaha dealer adjust it.
cC
Be sure to close the louver when
riding in the rain and when wash-
ing the scooter.
6-23
5SJ-28199-E2 8/9/02 4:06 PM Page 73
6-24
5SJ-28199-E2 8/9/02 4:06 PM Page 74
6-25
5SJ-28199-E2 8/9/02 4:06 PM Page 75
The tire tread depth limits may differ To maximize the performance, dura-
from country to country. Always com- 8 Have a Yamaha dealer replace bility, and safe operation of your
ply with the local regulations. excessively worn tires. scooter, note the following points
Besides being illegal, operat- regarding the specified wheels.
Tire information ing the scooter with exces- 8 The wheel rims should be
This scooter is equipped with tube- sively worn tires decreases checked for cracks, bends or
less tires. riding stability and can lead to warpage before each ride. If any
FRONT
loss of control. damage is found, have a
Manufacturer Size Model 8 The replacement of all wheel Yamaha dealer replace the
IRC 110/90-12 64L MB67 and brake related parts, wheel. Do not attempt even the
MICHELIN 110/90-12 64L BOPPER including the tires, should be smallest repair to the wheel. A
REAR
left to a Yamaha dealer, who deformed or cracked wheel must
Manufacturer Size Model has the necessary profession- be replaced. 6
IRC 130/70-12 62L MB67 al knowledge and experience. 8 The wheel should be balanced
MICHELIN 130/70-12 62L BOPPER whenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.
6-26
5SJ-28199-E2 8/9/02 4:06 PM Page 76
w
If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this adjust-
ment.
6-27
5SJ-28199-E2 8/9/02 4:06 PM Page 77
1 1
1
1. Wear indicator groove 1. Minimum level mark 1. Minimum level mark
EAU03939 EAU04856
Observe these precautions:
Rear brake pads Checking the brake fluid 8 When checking the fluid level,
Each rear brake pad is provided with level Brake fluid level, checking
6-29
5SJ-28199-E2 8/9/02 4:06 PM Page 79
fluid. Mixing fluids may result in a Changing the brake fluid Brake fluid, changing Checking and lubricating the
harmful chemical reaction and Have a Yamaha dealer change the cables Cables, checking and lubricating
lead to poor braking perfor- brake fluid at the intervals specified in The operation of all control cables
mance. the NOTE after the periodic mainte- and the condition of the cables
8 Be careful that water does not nance and lubrication chart. In addi- should be checked before each ride,
enter the brake fluid reservoir tion, have the oil seals of the master and the cables and cable ends
when refilling. Water will signifi- cylinders and calipers as well as the should be lubricated if necessary. If
cantly lower the boiling point of brake hoses replaced at the intervals a cable is damaged or does not move
the fluid and may result in vapor listed below or whenever they are smoothly, have a Yamaha dealer
lock. damaged or leaking. check or replace it.
8 Brake fluid may deteriorate paint- 8 Oil seals: Replace every two
years. Recommended lubricant:
ed surfaces or plastic parts. Engine oil
Always clean up spilled fluid 8 Brake hoses: Replace every four
years. EW000112 6
immediately. w
8 As the brake pads wear, it is nor-
Damage to the outer sheath may
mal for the brake fluid level to
interfere with proper cable opera-
gradually go down. However, if
tion and will cause the inner cable
the brake fluid level goes down
to rust. Replace a damaged cable
suddenly, have a Yamaha dealer
as soon as possible to prevent
check the cause.
unsafe conditions.
6-30
5SJ-28199-E2 8/9/02 4:06 PM Page 80
EAU03118 EAU03371
The pivoting points of the front and The operation of the centerstand and
6 rear brake levers must be lubricated sidestand should be checked before
at the intervals specified in the peri- each ride, and the pivots and metal-
odic maintenance and lubrication to-metal contact surfaces should be
chart. lubricated if necessary.
EW000114
Recommended lubricant:
w
Lithium-soap-based grease If the centerstand or sidestand
(all-purpose grease) does not move up and down
smoothly, have a Yamaha dealer
check or repair it.
6-31
5SJ-28199-E2 8/9/02 4:06 PM Page 81
w
Recommended lubricant: To check the operation
Securely support the scooter so
Lithium-soap-based grease 1. Place the scooter on a level sur-
that there is no danger of it falling
(all-purpose grease) face and hold it in an upright
over.
position.
6
2. While applying the front brake,
Check the inner tubes for scratches, push down hard on the handle-
damage and excessive oil leakage. bars several times to check if the
front fork compresses and
rebounds smoothly.
EC000098
cC
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
6-32
5SJ-28199-E2 8/9/02 4:06 PM Page 82
Checking the steering Steering, checking Checking the wheel bearings Wheel bearings, checking
Worn or loose steering bearings may The front and rear wheel bearings
cause danger. Therefore, the opera- must be checked at the intervals
tion of the steering must be checked specified in the periodic maintenance
as follows at the intervals specified in and lubrication chart. If there is play
the periodic maintenance and lubrica- in the wheel hub or if the wheel does
tion chart. not turn smoothly, have a Yamaha
1. Place a stand under the engine dealer check the wheel bearings.
to raise the front wheel off the
ground.
EW000115
2. Hold the lower ends of the front
w fork legs and try to move them
forward and backward. If any
Securely support the scooter so
free play can be felt, have a
6 that there is no danger of it falling
Yamaha dealer check or repair
over.
the steering.
6-33
5SJ-28199-E2 8/9/02 4:06 PM Page 83
3
1 1
6-34
5SJ-28199-E2 8/9/02 4:06 PM Page 84
6-35
5SJ-28199-E2 8/9/02 4:06 PM Page 85
6-36
5SJ-28199-E2 8/9/02 4:06 PM Page 86
6-37
5SJ-28199-E2 8/9/02 4:06 PM Page 87
1. Headlight bulb holder a. Do not touch the glass part of the bulb.
EC000105
4. Unhook the headlight bulb hold- 5. Place a new headlight bulb into
cC
er, and then remove the defec- position, and then secure it with
tive bulb. the bulb holder. Do not touch the glass part of the
EW000119 headlight bulb to keep it free from
w oil, otherwise the transparency of 6
Headlight bulbs get very hot. the glass, the luminosity of the
Therefore, keep flammable prod- bulb, and the bulb life will be
ucts away from a lit headlight bulb, adversely affected. Thoroughly
and do not touch the bulb until it clean off any dirt and fingerprints
has cooled down. on the headlight bulb using a cloth
moistened with alcohol or thinner.
6-38
5SJ-28199-E2 8/9/02 4:06 PM Page 88
1. Socket
6-39
5SJ-28199-E2 8/9/02 4:06 PM Page 89
1. Place the scooter on the center- 1. Place the scooter on the center-
stand. stand.
2. Remove cowling C. (See page 2. Remove cowling C. (See page
6-10 for cowling removal and 1 6-10 for cowling removal and
installation procedures.) installation procedures.)
1. Socket
6-40
5SJ-28199-E2 8/9/02 4:06 PM Page 90
6-41
5SJ-28199-E2 8/9/02 4:06 PM Page 91
Troubleshooting Troubleshooting
6-42
5SJ-28199-E2 8/9/02 4:06 PM Page 92
w
Keep away open flames and do not smoke while checking or working on the fuel system.
1. Fuel
There is enough fuel. Check the compression.
Check the fuel level in
the fuel tank.
The engine does not start.
There is no fuel. Supply fuel.
Check the compression.
2. Compression
There is compression. Check the ignition.
3. Ignition Wipe off with a dry cloth and correct the Open the throttle halfway and operate
Wet
spark plug gap, or replace the spark plug. the electric starter.
Remove the spark plug
and check the electrodes.
The engine does not start.
Dry Have a Yamaha dealer check the vehicle.
Check the battery.
6-43
5SJ-28199-E2 8/9/02 4:06 PM Page 93
w
8 Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
8 After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the
hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the
cap.
The coolant level Start the engine. If the engine overheats again, have a
is OK. Yamaha dealer check and repair the cooling system.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.
6-44
5SJ-28199-E2 8/9/02 4:06 PM Page 94
5SJ-28199-E2 8/9/02 4:06 PM Page 95
Care ...................................................................................................7-1
Storage ..............................................................................................7-4
7
5SJ-28199-E2 8/9/02 4:06 PM Page 96
EAU03434
7-1
5SJ-28199-E2 8/9/02 4:06 PM Page 97
7-2
5SJ-28199-E2 8/9/02 4:06 PM Page 98
7-3
5SJ-28199-E2 8/9/02 4:06 PM Page 99
w
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turn-
ing the engine over.
7-4
5SJ-28199-E2 8/9/02 4:06 PM Page 100
7-5
5SJ-28199-E2 8/9/02 4:06 PM Page 101
SPECIFICATIONS
Specifications ....................................................................................8-1
Conversion table ................................................................................8-5
8
5SJ-28199-E2 8/9/02 4:06 PM Page 102
EAU01038
SPECIFICATIONS
Specifications
Specifications
Specifications
8-1
5SJ-28199-E2 8/9/02 4:06 PM Page 103
SPECIFICATIONS
8-2
5SJ-28199-E2 8/9/02 4:06 PM Page 104
SPECIFICATIONS
Fluid DOT 4
8-3
5SJ-28199-E2 8/9/02 4:06 PM Page 105
SPECIFICATIONS
8-4
5SJ-28199-E2 8/9/02 4:06 PM Page 106
SPECIFICATIONS
EAU04513
8-5
5SJ-28199-E2 8/9/02 4:06 PM Page 107
CONSUMER INFORMATION
9
5SJ-28199-E2 8/9/02 4:06 PM Page 108
EAU01039
CONSUMER INFORMATION
EAU02944
Key identification number Key identification number Vehicle identification number Vehicle identification number
9-1
5SJ-28199-E2 8/9/02 4:06 PM Page 109
CONSUMER INFORMATION
1. Model label
EAU03097
9-2
5SJ-28199-E2 8/9/02 4:06 PM Page 110
INDEX
A E I
Acceleration and deceleration ................5-3 Engine break-in ......................................5-4 Identification numbers ............................9-1
Air filter and V-belt case air filter Engine oil ..............................................6-14 Ignition circuit cut-off system ................3-21
elements, cleaning .............................6-21 Indicator lights ........................................3-2
Air flow louver .......................................6-23 F High beam indicator light .....................3-2
Anti-theft alarm (optional) .......................3-9 Final transmission oil ............................6-18 Oil change indicator light .....................3-2
Front and rear brake lever free play, Turn signal indicator lights ...................3-2
B adjusting ............................................6-27
Battery ..................................................6-34 Front and rear brake pads, checking ....6-28 K
Battery cover removal ..........................6-34 Front fork, checking ..............................6-32 Key identification number .......................9-1
Brake fluid level, checking ....................6-29 Fuel ......................................................3-14
Brake fluid, changing ............................6-30 Fuel consumption, tips for reducing .......5-4 L
Brake lever, front ..................................3-12 Fuel gauge .............................................3-4 License plate light bulb, replacing ........6-41
Brake lever, rear ...................................3-13 Fuel tank cap ........................................3-13
Brake levers, lubricating .......................6-31 Fuses, replacing ...................................6-36 M
Braking ...................................................5-3 Main switch/steering lock .......................3-1
H Model label .............................................9-2
C Handlebar switches ..............................3-10
Cables, checking and lubricating ..........6-30 Dimmer switch ...................................3-10 P
Care ........................................................7-1 Engine stop switch .............................3-12 Parking ...................................................5-5
Catalytic converter ................................3-15 Horn switch ........................................3-10 Part locations ..........................................2-1
Centerstand and sidestand, checking Pass switch ........................................3-10 Periodic maintenance and lubrication
and lubricating ...................................6-31 Start switch ........................................3-12 chart .....................................................6-3
Conversion table ....................................8-5 Turn signal switch ..............................3-10 Pre-operation check list ..........................4-1
Coolant .................................................6-19 Headlight bulb, replacing ......................6-37
Coolant temperature gauge ....................3-5 Headlight variations ..............................3-11 R
Cowlings and panel, removing and Rider seat .............................................3-16
installing ...............................................6-6 Rider seat, adjusting .............................3-17
D
Display, multi-function ............................3-5
5SJ-28199-E2 8/9/02 4:06 PM Page 111
INDEX
S W
Safe-riding points ...................................1-2 Wheel bearings, checking ....................6-33
Shock absorber assemblies, Wheels .................................................6-26
adjusting ............................................3-19
Sidestand .............................................3-20
Spark plug, checking ............................6-12
Specifications .........................................8-1
Speedometer ..........................................3-3
Starting off ..............................................5-2
Starting the engine .................................5-1
Steering, checking ................................6-33
Storage ...................................................7-4
Storage compartments .........................3-17
T
Tachometer ............................................3-3
Tail/brake light bulb, replacing ..............6-40
Throttle cable free play, adjusting ........6-23
Throttle grip and cable, checking and
lubricating ..........................................6-31
Tires .....................................................6-24
Tool kit ....................................................6-1
Troubleshooting ....................................6-42
Troubleshooting charts .........................6-43
Turn signal light bulb (front),
replacing ............................................6-39
Turn signal light bulb (rear),
replacing ............................................6-40
V
Valve clearance, adjusting ...................6-23
Vehicle identification number .................9-1
5SJ-28199-E2 8/9/02 4:06 PM Page 112
5SJ-28199-E2 8/9/02 4:06 PM Page 112
OWNER’S MANUAL