light YAMAHA VERSITY 300 2005 User Guide

INSTRUMENT AND CONTROL FUNCTIONS
3-15
3
EAU15300
Sidestand The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.NOTE:The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation ofthe ignition circuit cut-off system.)
WARNING
EWA10240
The vehicle must not be ridden with
the sidestand down, or if the side-
stand cannot be properly moved up(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
Yamaha’s ignition circuit cut-off
system has been designed to assist
the operator in fulfilling the respon-
sibility of raising the sidestand be-
fore starting off. Therefore, check
this system regularly as described
below and have a Yamaha dealer re-
pair it if it does not function proper-
ly.
EAU15371
Ignition circuit cut-off system The ignition circuit cut-off system (com-
prising the sidestand switch and brake
light switches) has the following func-
tions.

It prevents starting when the side-
stand is up, but neither brake is ap-
plied.


It prevents starting when either
brake is applied, but the sidestand
is still down.


It cuts the running engine when the
sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.WARNING
EWA10250
If a malfunction is noted, have a
Yamaha dealer check the system be-fore riding.
1. Sidestand switch
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PRE-OPERATION CHECKS
4-3
4
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-17, 6-19
Brake leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-22
Centerstand, sidestandMake sure that operation is smooth.
Lubricate pivots if necessary.6-23
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-15 ITEM CHECKS PAGE

OPERATION AND IMPORTANT RIDING POINTS
5-3
5


Keep in mind that braking on a
wet road is much more difficult.


Ride slowly down a hill, as brak-
ing downhill can be very diffi-cult.
EAU16820
Tips for reducing fuel
consumption Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

Avoid high engine speeds during
acceleration.


Avoid high engine speeds with no
load on the engine.


Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16841
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAUM2010
0–1000 km (0–600 mi)
Avoid prolonged operation above 1/3
throttle.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 1/2
throttle.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAUM2070
NOTE:

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years change the brake fluid.Replace the brake hoses every four years and if cracked or damaged.
23*V- b e l tReplace. Every 20000 km
24*Front and rear brake
switchesCheck operation.√√√√√ √
25Moving parts and ca-
blesLubricate.√√√√ √
26*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
27*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
EAUM2020
Cowling A
To remove the cowling1. Pull up the floorboard mat on each
side of the scooter.
2. Remove panel A. (See page 6-7.)
3. Remove the cowling screws.4. Disconnect the headlight coupler
and the turn signal coupler.
5. Pull the cowling off.To install the cowling
1. Connect the headlight coupler and
the turn signal coupler.
2. Place the cowling in the original
position, and then install the
screws.
3. Install the panel.
4. Place the floorboard mats in their
original position.
EAUM1520
Cowling B
To remove the cowling1. Pull up the floorboard mat on each
side of the scooter.
1. Panel D
1. Panel E
1
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1. Cowling A
2. Screw
3. Floorboard mat
1. Turn signal light lead coupler
2. Headlight coupler
3 2 1
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12
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1. Floorboard mat
1
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6To install the panel
Place the panel in the original position,
and then install the screw.
EAU19630
Checking the spark plug 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 mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug
1. Remove cowling B. (See page
6-6.)
2. Remove the spark plug cap.3. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
NOTE:If the spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have aYamaha dealer check the vehicle.
1. Panel E
2. Screw
1
2
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1. Spark plug cap
1
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1. Spark plug wrench
1
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-fied torque as soon as possible.
4. Install the spark plug cap.
5. Install the cowling.
EAUM1550
Engine oil The engine oil level should be checked
before each ride. In addition, the oil
must be changed at the intervals spec-
ified in the periodic maintenance and
lubrication chart and when the service
indicator light comes on.
To check the engine oil level
1. Place the scooter on the center-
stand.NOTE:Make sure that the scooter is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result ina false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
Specified spark plug:
NGK/DR8EA1. Spark plug gapSpark plug gap:
0.6–0.7 mm (0.024–0.028 in)
1
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Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 12.5 ft·lbf)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
66. Add the specified amount of the
recommended final transmission
oil, and then install and tighten the
oil filler cap.
WARNING
EWA11310


Make sure that no foreign mate-
rial enters the final transmission
case.


Make sure that no oil gets on thetire or wheel.
7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
EAU20070
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU20230
To check the coolant level
The coolant reservoir is located under
the battery cover. (See page 6-7.)
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.NOTE:

The coolant level must be checked
on a cold engine since the level
varies with engine temperature.


Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to theside can result in a false reading.
2. Check the coolant level in the cool-
ant reservoir.
NOTE:The coolant should be between theminimum and maximum level marks.
3. If the coolant is at or below the
minimum level mark, remove the
reservoir cap, add coolant to the
maximum level mark, and then in-
stall the reservoir cap.
Recommended final transmission
oil:
See page 8-1.
Oil quantity:
0.25 L (0.26 US qt) (0.22 Imp.qt)
1. Maximum level mark
2. Minimum level mark
1
2
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
The fuse block, which contains the fus-
es for the individual circuits, is located
in the storage compartment A. (See
page 3-12.)
If a fuse is blown, replace it as follows.
1. Turn the key to “” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
CAUTION:
ECA10640
Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly afire.
3. Turn the key to “” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAU23841
Replacing the headlight bulb This model is equipped with a quartz
bulb headlight. If the headlight bulb
burns out, replace it as follows.
1. Remove cowling A together with
the headlight unit. (See page 6-6.)
2. Disconnect the headlight coupler,
and then remove the bulb cover.
3. Remove the headlight bulb holder
by pushing it inward and turning it
counterclockwise, and then re-
move the defective bulb.
1. Backup fuse
2. Headlight fuse
3. Radiator fan fuse
4. Signaling system fuse
5. Ignition fuse
6. Auxiliary DC jack fuse
7. Spare fuse
8. Fuse tongs
12345 776
8
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Specified fuses:
Main fuse:
30.0 A
Backup fuse:
3.0 A
Headlight fuse:
15.0 A
Radiator fan fuse:
15.0 A
Signaling system fuse:
15.0 A
Ignition fuse:
7.5 A
Auxiliary DC jack fuse:
3.0 A
1. Bulb cover
2. Headlight coupler
2 1
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6
WARNING
EWA10790
Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooleddown.
4. Place a new headlight bulb into po-
sition, and then secure it with the
bulb holder.
CAUTION:
ECA10660
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 the bulb life will be adversely af-
fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with al-cohol or thinner.
5. Install the headlight bulb cover,
and then connect the coupler.
6. Install the cowling together with
the headlight unit.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAUT1260
Replacing a front turn signal
light bulb CAUTION:
ECA10670
It is advisable to have a Yamahadealer perform this job.
1. Place the scooter on the center-
stand.
2. Remove cowling A. (See page
6-6.)
3. Remove the socket (together with
the bulb) by turning it counter-
clockwise.
4. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
1. Headlight bulb holder
1
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1. Do not touch the glass part of the bulb.
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1. Turn signal light bulb socket
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