belt YAMAHA VERSITY 300 2005 Owners Manual

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
Further safe-riding points ................1-4
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Main switch/steering lock ................3-1
Indicator lights ................................3-2
Speedometer ..................................3-2
Fuel gauge ......................................3-3
Battery voltage/coolant temperature
gauge ..........................................3-3
Multi-function display ......................3-4
Anti-theft alarm (optional) ...............3-7
Handlebar switches ........................3-7
Front brake lever ............................3-8
Rear brake lever .............................3-9
Fuel tank cap ..................................3-9
Fuel ...............................................3-10
Catalytic converter ........................3-11
Seat ..............................................3-11
Storage compartment ...................3-12
Storage compartment ...................3-12
Storage compartment ...................3-13
Anti-theft device housing ..............3-13
Adjusting the shock absorber
assemblies ................................3-14Luggage hook .............................. 3-14
Sidestand ..................................... 3-15
Ignition circuit cut-off system ........ 3-15
Auxiliary DC jack .......................... 3-17
PRE-OPERATION CHECKS............. 4-1
Pre-operation check list .................. 4-2
OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting the engine ......................... 5-1
Starting off ...................................... 5-2
Acceleration and deceleration ........ 5-2
Braking ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Removing and installing cowlings
and panels .................................. 6-5
Checking the spark plug ................. 6-9
Engine oil ..................................... 6-10
Final transmission oil .................... 6-12
Coolant ......................................... 6-13Air filter and V-belt case air filter
elements ................................... 6-14
Adjusting the carburetor ............... 6-16
Checking the throttle cable free
play ........................................... 6-16
Valve clearance ........................... 6-17
Tires ............................................. 6-17
Cast wheels ................................. 6-19
Checking the front and rear brake
lever free play ........................... 6-19
Checking the front and rear brake
pads .......................................... 6-20
Checking the brake fluid level ...... 6-20
Changing the brake fluid .............. 6-21
Checking and lubricating the
cables ....................................... 6-22
Checking and lubricating the throttle
grip and cable ........................... 6-22
Lubricating the front and rear brake
levers ........................................ 6-22
Checking and lubricating the
centerstand and sidestand ....... 6-23
Checking the front fork ................. 6-23
Checking the steering .................. 6-24
Checking the wheel bearings ....... 6-25
Battery ......................................... 6-25
Replacing the fuses ..................... 6-26
Replacing the headlight bulb ....... 6-27
Replacing a front turn signal light
bulb ........................................... 6-28

DESCRIPTION
2-1
2
EAU10410
Left view
1
65 4 3 2
1. Rear storage compartment (page 3-13)
2. Shock absorber assembly spring preload adjusting ring (page 3-14)
3. Air filter element (page 6-14)
4. V-belt case air filter element (page 6-14)
5. Sidestand (page 3-15/6-23)
6. Coolant level check window (page 6-13)

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU17705
Periodic maintenance and lubrication chart NOTE:

The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.


From 50000 km, repeat the maintenance intervals starting from 10000 km.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
1*Fuel lineCheck fuel and vacuum hoses for cracks or damage.√√√√ √
2 Spark plugCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.√√
4 Air filter elementClean.√√
Replace.√√
5V-belt case air filter ele-
mentClean.√√√√
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
8*Brake hosesCheck for cracks or damage.√√√√ √
Replace. Every 4 years

PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6 4. Install the battery cover.
CAUTION:
ECA10470


If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.


If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the engine may not besufficiently cooled and the cool-
ing system will not be protected
against frost and corrosion.


If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness ofthe coolant will be reduced.
NOTE:

The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.


If the engine overheats, see page6-31 for further instructions.
EAU33030
Changing the coolant
WARNING
EWA10380
Never attempt to remove the radiatorcap when the engine is hot.
The coolant must be changed at the in-
tervals specified in the periodic mainte-
nance and lubrication chart. Have a
Yamaha dealer change the coolant.
EAUM2030
Air filter and V-belt case air
filter elements The air filter and V-belt case air filter el-
ements should be cleaned at the inter-
vals specified in the periodic
maintenance and lubrication chart.
Clean both filter elements more fre-
quently if you are riding in unusually
wet or dusty areas.CAUTION:
ECA10530


Make sure that each filter ele-
ment is properly seated in its
case.


The engine should never be op-
erated without the filter ele-
ments installed, otherwise the
piston(s) and/or cylinder(s) maybecome excessively worn.
Cleaning the air filter element
1. Place the scooter on the center-
stand.
2. Remove the air filter case cover by
removing the screws.
1. Coolant reservoir capCoolant reservoir capacity (up to the
maximum level mark):
0.40 L (0.42 US qt) (0.35 Imp.qt)
1
ZAUM0445

PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
63. Pull the sponge material out along
with the mesh sheet, clean it with
solvent, and then squeeze the re-
maining solvent out.
4. Check the sponge material for
damage and replace it if neces-
sary.
5. Allow the sponge material to dry.
6. Apply oil of the recommended type
to the entire surface of the sponge
material, and then squeeze the ex-
cess oil out.
NOTE:The sponge material should be wet butnot dripping.
7. Insert the sponge material into the
air filter case.
8. Install the air filter case cover by in-
stalling the screws.
Cleaning the V-belt case air filter el-
ement
1. Remove the air filter case cover by
removing the screws.
2. Remove the V-belt case air filter
cover by removing the screws.3. Blow the dirt out of the air filter ele-
ment with compressed air as
shown.
4. Check the V-belt case air filter ele-
ment for damage and replace it if
necessary.
1. Air filter case cover
2. Screw
3. Sponge material
4. Mesh sheet1
2 2
3
4
ZAUM0446
Recommended oil:
Foam air filter oilZAUM0447
1. V-belt case air filter cover
2. Screw
1. V-belt case air filter cover
2. V-belt case air filter element

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6 5. Install the V-belt case air filter ele-
ment cover by installing the
screws.
6. Install the air filter case cover by in-
stalling the screws.
EAU21300
Adjusting the carburetor The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, all carbu-
retor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience.
EAU21381
Checking the throttle cable
free play The throttle cable free play should mea-
sure 1.5–3.0 mm (0.06–0.12 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, have a Yamaha dealer adjust it.1. Throttle cable free play1ZAUM0051

SPECIFICATIONS
8-1
8
Dimensions:Overall length:
2170 mm (85.4 in)
Overall width:
765 mm (30.1 in)
Overall height:
1465 mm (57.7 in)
Seat height:
805 mm (31.7 in)
Wheelbase:
1480 mm (58.3 in)
Ground clearance:
155 mm (6.10 in)
Minimum turning radius:
1706 mm (67.2 in)Weight:With oil and fuel:
174.0 kg (384 lb)Engine:Engine type:
Liquid cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
264.0 cm³ (16.11 cu.in)
Bore × stroke:
71.0 × 66.8 mm (2.80 × 2.63 in)
Compression ratio:
10.00 :1
Starting system:
Electric starter
Lubrication system:
Wet sump
Engine oil:Type:
SAE10W30 or SAE10W40 or SAE15W40
or SAE20W40 or SAE20W50
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine oil quantity:
Periodic oil change:
1.20 L (1.27 US qt) (1.06 Imp.qt)Final transmission oil:Type:
SAE10W30 type SE motor oil
Quantity:
0.25 L (0.26 US qt) (0.22 Imp.qt)Cooling system:Coolant reservoir capacity (up to the
maximum level mark):
0.40 L (0.42 US qt) (0.35 Imp.qt)
Radiator capacity (including all routes):
1.60 L (1.69 US qt) (1.41 Imp.qt)
Air filter:Air filter element:
Wet elementFuel:Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
10.9 L (2.88 US gal) (2.40 Imp.gal)
Fuel reserve amount:
1.9 L (0.50 US gal) (0.42 Imp.gal)Carburetor:Manufacturer:
TEIKEI
Type x quantity:
Y28V-1J x 1Spark plug(s):Manufacturer/model:
NGK/DR8EA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)Clutch:Clutch type:
Dry, centrifugal automaticTransmission:Primary reduction system:
Helical gear
Primary reduction ratio:
40/15 (2.666)
Secondary reduction system:
Helical gear
Secondary reduction ratio:
37/12 (3.083)
Transmission type:
V-belt automatic
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40

INDEX
AAcceleration and deceleration ................ 5-2
Air filter and V-belt case air filter
elements, cleaning ............................. 6-14
Anti-theft alarm (optional) ....................... 3-7
Anti-theft device housing ...................... 3-13
Auxiliary DC jack .................................. 3-17BBattery .................................................. 6-25
Battery voltage/coolant temperature
gauge ................................................... 3-3
Brake fluid, changing ............................ 6-21
Brake fluid level, checking .................... 6-20
Brake lever, front .................................... 3-8
Brake lever, rear ..................................... 3-9
Brake levers, lubricating ....................... 6-22
Braking ................................................... 5-2CCables, checking and lubricating .......... 6-22
Carburetor,adjusting ............................. 6-16
Care ........................................................ 7-1
Catalytic converter ................................ 3-11
Centerstand and sidestand, checking
and lubricating .................................... 6-23
Coolant ................................................. 6-13
Cowlings and panels, removing and
installing ............................................... 6-5DDimmer switch ........................................ 3-7
Display, multi-function ............................ 3-4EEngine break-in ...................................... 5-3
Engine oil .............................................. 6-10
Engine stop switch.................................. 3-8
FFinal transmission oil.............................6-12
Front and rear brake lever free play,
checking .............................................. 6-19
Front and rear brake pads, checking .... 6-20
Front fork, checking...............................6-23
Fuel ....................................................... 3-10
Fuel consumption, tips for reducing ........ 5-3
Fuel gauge .............................................. 3-3
Fuel tank cap........................................... 3-9
Fuses, replacing .................................... 6-26HHandlebar switches ................................. 3-7
Hazard switch.......................................... 3-8
Headlight bulb, replacing....................... 6-27
High beam indicator light......................... 3-2
Horn switch ............................................. 3-8IIdentification numbers ............................. 9-1
Ignition circuit cut-off system ................. 3-15
Indicator lights .........................................3-2KKey identification number ........................ 9-1LLicense plate light bulb, replacing ......... 6-30
Low beam indicator light ......................... 3-2
Luggage hook ....................................... 3-14MMain switch/steering lock ........................ 3-1
Model label .............................................. 9-2PParking ....................................................5-4
Part locations .......................................... 2-1
Pass switch ............................................. 3-7Periodic maintenance and lubrication
chart...................................................... 6-2
Pre-operation check list .......................... 4-2
SSafe-riding points .................................... 1-4
Safety information ................................... 1-1
Seat ...................................................... 3-11
Shock absorber assemblies,
adjusting ............................................. 3-14
Sidestand .............................................. 3-15
Spark plug, checking .............................. 6-9
Specifications.......................................... 8-1
Speedometer .......................................... 3-2
Starting off .............................................. 5-2
Starting the engine.................................. 5-1
Start switch ............................................. 3-8
Steering, checking ................................ 6-24
Storage ................................................... 7-3
Storage compartment .................. 3-12, 3-13TTail/brake light bulb or rear turn signal
light bulb, replacing............................. 6-29
Throttle cable free play, checking ......... 6-16
Throttle grip and cable, checking and
lubricating ........................................... 6-22
Tires ...................................................... 6-17
Tool kit .................................................... 6-1
Troubleshooting .................................... 6-30
Troubleshooting charts ......................... 6-31
Turn signal indicator lights ...................... 3-2
Turn signal light bulb (front),
replacing ............................................. 6-28
Turn signal switch ................................... 3-7