check engine YAMAHA AEROX50 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
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Main switch/steering lock ................3-1
Indicator and warning lights ............3-2
Speedometer unit ...........................3-3
Tachometer (Depends on
models) ........................................3-3
Fuel gauge ......................................3-4
Handlebar switches ........................3-4
Front brake lever ............................3-5
Rear brake lever .............................3-5
Fuel tank cap ..................................3-5
Fuel .................................................3-6
Catalytic converter ..........................3-7
2-stroke engine oil tank ..................3-7
2-stroke engine oil ..........................3-8
Kickstarter .......................................3-8
Rider seat .......................................3-8
Storage compartment A...................3-9
Storage compartment B.................3-10
Adjusting the shock absorber
assembly (Depends on
models) ......................................3-10PRE-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 ........................................... 5-3
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-4
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Removing and installing the
cowling and panel ....................... 6-5
Checking the spark plug ................. 6-6
Final transmission oil ...................... 6-7
Coolant ........................................... 6-8
Cleaning the air filter element ........ 6-9
Adjusting the carburetor ............... 6-10
Checking the throttle cable free
play ........................................... 6-11
Tires ............................................. 6-11
Cast wheels .................................. 6-13
Checking the front and rear brake
lever free play ........................... 6-13Checking the front and rear brake
pads .......................................... 6-14
Checking the brake fluid level ...... 6-15
Changing the brake fluid .............. 6-15
Checking and lubricating the
throttle grip and cable ............... 6-16
Lubricating the front and rear brake
levers ........................................ 6-16
Checking and lubricating the
centerstand............................... 6-16
Checking the front fork ................. 6-17
Checking the steering .................. 6-17
Checking the wheel bearings ....... 6-18
Battery ......................................... 6-18
Replacing the fuse ....................... 6-20
Replacing the headlight bulb ....... 6-21
Replacing the tail/brake light
bulb ........................................... 6-21
Replacing a turn signal light
bulb ........................................... 6-22
Troubleshooting ........................... 6-22
Troubleshooting charts ................ 6-23
SCOOTER CARE AND STORAGE... 7-1
Care ............................................... 7-1
Storage .......................................... 7-3
SPECIFICATIONS ............................ 8-1
CONSUMER INFORMATION............ 9-1
Identification numbers .................... 9-1

SAFETY INFORMATION
1-3
1 Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit of
180 kg (397 lb). When loading within
this weight limit, keep the following in
mind:

Cargo and accessory weight
should be kept as low and close to
the scooter as possible. Make sure
to distribute the weight as evenly
as possible on both sides of the
scooter to minimize imbalance or
instability.


Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the scooter before
riding. Check accessory mounts
and cargo restraints frequently.


Never attach any large or heavy
items to the handlebar, front fork,
or front fender. Such items can
create unstable handling or a slow
steering response.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this scooter. Since Yamaha cannot testall other accessories that may be avail-
able, you must personally be responsi-
ble for the proper selection, installation
and use of non-Yamaha accessories.
Use extreme caution when selecting
and installing any accessories.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.


Never install accessories or carry
cargo that would impair the perfor-
mance of your scooter. Carefully
inspect the accessory before using
it to make sure that it does not in
any way reduce ground clearance
or cornering clearance, limit sus-
pension travel, steering travel or
control operation, or obscure lights
or reflectors.
Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.Bulky or large accessories may
seriously affect the stability of
the scooter due to aerodynamic
effects. Wind may attempt to lift
the scooter, or the scooter may
become unstable in cross
winds. These accessories may
also cause instability when
passing or being passed by
large vehicles.
Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.


Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
scooter’s electrical system an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.

SAFETY INFORMATION
1-4
1Gasoline and exhaust gas


GASOLINE IS HIGHLY FLAMMA-
BLE:
Always turn the engine off when
refueling.
Take care not to spill any gaso-
line on the engine or exhaust
system when refueling.
Never refuel while smoking or in
the vicinity of an open flame.


Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within a
short time. Always operate your
scooter in an area that has ade-
quate ventilation.


Always turn the engine off before
leaving the scooter unattended
and remove the key from the main
switch. When parking the scooter,
note the following:
The engine and exhaust system
may be hot, therefore, park the
scooter in a place where pedes-
trians or children are not likely to
touch these hot areas.Do not park the scooter on a
slope or soft ground, otherwise it
may fall over.
Do not park the scooter near a
flammable source (e.g., a kero-
sene heater, or near an open
flame), otherwise it could catch
fire.


If you should swallow any gaso-
line, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediately.
If any gasoline spills on your skin
or clothing, immediately wash the
affected area with soap and water
and change your clothes.
EAU10371
Further safe-riding points

Be sure to signal clearly when
making turns.


Braking can be extremely difficult
on a wet road. Avoid hard braking,
because the scooter could slide.
Apply the brakes slowly when
stopping on a wet surface.


Slow down as you approach a cor-
ner or turn. Once you have com-
pleted a turn, accelerate slowly.


Be careful when passing parked
cars. A driver might not see you
and open a door in your path.


Railroad crossings, streetcar rails,
iron plates on road construction
sites, and manhole covers be-
come extremely slippery when
wet. Slow down and cross them
with caution. Keep the scooter up-
right, otherwise it could slide out
from under you.


The brake pads could get wet
when you wash the scooter. After
washing the scooter, check the
brakes before riding.

INSTRUMENT AND CONTROL FUNCTIONS
3-1
3
EAU10460
Main switch/steering lock The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.
EAU10640
ON “”
All electrical circuits are supplied with
power, and the engine can be started.
The key cannot be removed.NOTE:The headlight, meter lighting and tail-
light come on automatically when theengine is started.
EAU10660
OFF “”
All electrical systems are off. The key
can be removed.
EAU10670
CHECK “”
The 2-stroke engine oil level warning
light should come on. (See page 3-2.)
EAU10680
LOCK “”
The steering is locked, and all electrical
systems are off. The key can be re-
moved.
To lock the steering1. Turn the handlebars all the way to
the left.
2. Push the key in from the “” posi-
tion, and then turn it to “” while
still pushing it.
3. Remove the key.
To unlock the steeringPush the key in, and then turn it to “”
while still pushing it.
WARNING
EWA10060
Never turn the key to “” or “”
while the vehicle is moving, other-
wise the electrical systems will be
switched off, which may result in
loss of control or an accident. Make
sure that the vehicle is stopped be-fore turning the key to “” or “”.
PUSHOPEN
ZAUM0253

INSTRUMENT AND CONTROL FUNCTIONS
3-2
3
EAU11002
Indicator and warning lights
EAU11020
Turn signal indicator light “”
This indicator light flashes when the
turn signal switch is pushed to the left or
right.
EAU11080
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU11180
Oil level warning light “”
This warning light comes on when the
key is in the “” position or when the oil
level in the 2-stroke engine oil tank is
low during operation. If the warninglight comes on during operation, stop
immediately and fill the oil tank with Ya-
malube 2 or equivalent 2-stroke engine
oil of either JASO grade “FC” or ISO
grades “EG-C” or “EG-D”. The warning
light should go off after the 2-stroke en-
gine oil tank has been refilled.
NOTE:If the warning light does not come on
when the key is in the “” position or
does not go off after the 2-stroke en-
gine oil tank has been refilled, have a
Yamaha dealer check the electrical cir-cuit.CAUTION:
ECA10010
Do not operate the vehicle until you
know that the engine oil level is suf-ficient.
EAU11430
Coolant temperature warning light
“”
This warning light comes on when the
engine overheats. When this occurs,
stop the engine immediately and allow
the engine to cool.CAUTION:
ECA10020
Do not operate the engine if it isoverheated.
1. Turn signal indicator light “”
2. High beam indicator light “”
3. Oil level warning light “”
TEMP
123
ZAUM0254
1. Coolant temperature warning light “”
TEMP
Km / h
E1/2
F
1
ZAUM0255

PRE-OPERATION CHECKS
4-2
4
EAU15603
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-6
2-stroke engine oilCheck oil level in oil tank.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.3-7, 3-8
Final transmission oilCheck vehicle for oil leakage. 6-7
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-8
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-13, 6-14, 6-15
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-13, 6-14, 6-15
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-11, 6-16

OPERATION AND IMPORTANT RIDING POINTS
5-1
5
EAU15980
WARNING
EWA10870


Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.


Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.


For safety, always start the en-gine with the centerstand down.
EAU16560
Starting the engineCAUTION:
ECA10250
See page 5-4 for engine break-in in-
structions prior to operating the ve-hicle for the first time.
1. Turn the key to “”, and when the
oil level warning light comes on,
turn it to “”.CAUTION:
ECA10240
If the oil level warning light does not
come on, have a Yamaha dealercheck the electrical circuit.
2. Close the throttle completely.3. While applying the front or rear
brake, start the engine by pushing
the start switch or by pushing the
kickstarter lever down.
NOTE:If the engine fails to start by pushing the
start switch, release the switch, wait a
few seconds, and then try again. Each
starting attempt should be as short as
possible to preserve the battery. Do not
crank the engine more than 5 seconds
on any one attempt. If the engine does
not start with the starter motor, try usingthe kickstarter.
PUSHOPEN
ZAUM0253
ZAUM0367

OPERATION AND IMPORTANT RIDING POINTS
5-2
5
CAUTION:
ECA11040
For maximum engine life, never ac-
celerate hard when the engine iscold!
EAU16760
Starting off NOTE:Before starting off, allow the engine towarm up.
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 centerstand.
2. Sit astride the seat, and then ad-
just the rear view mirrors.
3. Switch the turn signal on.
4. Check for oncoming traffic, and
then slowly turn the throttle grip (on
the right) in order to take off.
5. Switch the turn signal off.
EAU16780
Acceleration and deceleration The speed can be adjusted by opening
and closing the throttle. To increase the
speed, turn the throttle grip in direction
(a). To reduce the speed, turn the throt-
tle grip in direction (b).
ZAUM0267
(b)
(a)
ZAUM0199

OPERATION AND IMPORTANT RIDING POINTS
5-4
5
EAU16830
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1000 km (600 mi). For
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
1000 km (600 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.
EAUM2090
0–150 km (0–90 mi)
Avoid prolonged operation above 1/3
throttle. Vary the speed of the scooter
from time to time. Do not operate it at
one set throttle position.
150–500 km (90–300 mi)
Avoid prolonged operation above 1/2
throttle.
500–1000 km (300–600 mi)
Avoid cruising speeds in excess of 3/4
throttle.
CAUTION:
ECAM1070
After 1000 km (600 mi) of operation,
the final transmission oil must bechanged.
1000 km (600 mi) and beyond
Avoid prolonged full throttle operation.
Vary speeds occasionally.CAUTION:
ECA10270
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealercheck the vehicle.
EAU17212
Parking When parking, stop the engine, and
then remove the key from the main
switch.
WARNING
EWA10310


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.


Do not park on a slope or on soft
ground, otherwise the vehiclemay overturn.
CAUTION:
ECA10380
Never park in an area where there
are fire hazards such as grass orother flammable materials.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
10*Wheel bearingsCheck bearing for looseness or damage.√√√√
11*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 24000 km
12*Chassis fastenersMake sure that all nuts, bolts and screws are properly
tightened.√√√√ √
13 CenterstandCheck operation.
Lubricate.√√√√ √
14*Front forkCheck operation and for oil leakage.√√√√
15*Shock absorber assem-
blyCheck operation and shock absorber for oil leakage.√√√√
16*CarburetorAdjust engine idling speed.√√√√√ √
17*Autolube pumpCheck operation.
Bleed if necessary.√√√√
18*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change. Every 3 years
19 Final transmission oilCheck vehicle for oil leakage.√√ √
Change.√√√
20*V- b e l tReplace. Every 10000 km
21*Front and rear brake
switchesCheck operation.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 6 12 18 24