YAMAHA AEROX50 2009 Service Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
6-10
6
EAU33031
Changing the coolant
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.
WARNING! Never attempt to remove
the radiator cap when the engine is
hot.
[EWA10381]EAUM1642
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove the air filter case cover by
removing the screws.
2. Pull the air filter element out, clean
it with solvent, and then squeeze
the remaining solvent out.
WARNING! Use only a dedicat-
ed parts cleaning solvent. To
avoid the risk of fire or explo-
sion, do not use gasoline or sol-
vents with a low flash point.
[EWA10431]
NOTICE: To avoid dam-
aging the foam material, handle
it gently and carefully, and do
not twist or wring it.
[ECA10511]
3. Apply oil of the recommended type
to the entire surface of the ele-
ment, and then squeeze the ex-
cess oil out.
1. Screw
1
ZAUM0275
1. Air filter element
1ZAUM02761
4 32ZAUM0156
U3C6E1E0.book Page 10 Friday, August 8, 2008 10:09 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
6
TIPThe air filter element should be wet butnot dripping.
4. Insert the element into the air filter
case. NOTICE: Make sure that
the air filter element is properly
seated in the air filter case. The
engine should never be operat-
ed without the air filter element
installed, otherwise the pis-
ton(s) and/or cylinder(s) may
become excessively worn.
[ECA10481]
5. 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.
EAU21382
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.
Recommended oil:
Foam air filter oil
1. Throttle cable free play1ZAUM0051
U3C6E1E0.book Page 11 Friday, August 8, 2008 10:09 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
6
EAU21872
Tires To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING
EWA10501
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or death from loss of
control.


The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).


The tire air pressure must be ad-
justed in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approvedfor this model.
WARNING
EWA10511
Never overload your vehicle. Opera-
tion of an overloaded vehicle couldcause an accident.
Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
ZAUM0053
Tire air pressure (measured on cold
tires):
0–90 kg (0–198 lb):
Fr o nt :
150 kPa (1.50 kgf/cm², 22 psi)
Rear:
150 kPa (1.50 kgf/cm², 22 psi)
90–180 kg (198–397 lb):
Fr o nt :
160 kPa (1.60 kgf/cm², 23 psi)
Rear:
170 kPa (1.70 kgf/cm², 25 psi)
Maximum load*:
180 kg (397 lb)
* Total weight of rider, passenger, car-
go and accessories
1. Tire tread depth
2. Tire sidewall
Minimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
1
2
ZAUM0054
U3C6E1E0.book Page 12 Friday, August 8, 2008 10:09 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
6
TIPThe tire tread depth limits may differ
from country to country. Always complywith the local regulations.
Tire information
This model is equipped with tubeless
tires.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
WARNING
EWA10470


Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.


The replacement of all wheel
and brake related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-edge and experience.
EAU21960
Cast wheels To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified wheels.

The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
Front tire:
Size:
130/60-13 53L (MICHELIN), 53P
(PIRELLI)
Manufacturer/model:
MICHELIN / PILOT SPORT
PIRELLI / EVO21
Rear tire:
Size:
140/60-13 57L (MICHELIN), 53P
(PIRELLI)
Manufacturer/model:
MICHELIN / PILOT SPORT
PIRELLI / EVO22
U3C6E1E0.book Page 13 Friday, August 8, 2008 10:09 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
6
EAUM2061
Checking the front and rear
brake lever free play The brake lever free play should mea-
sure 10.0–20.0 mm (0.39–0.79 in) as
shown. Periodically check the brake le-ver free play and, if necessary, have a
Yamaha dealer check the brake sys-
tem.
WARNING
EWA10641
An incorrect brake lever free play in-
dicates a hazardous condition in the
brake system. Do not operate the ve-
hicle until the brake system has
been checked or repaired by aYamaha dealer.
EAU22390
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22400
Front brake pads
Check each front brake pad for dam-
age and measure the lining thickness. If
a brake pad is damaged or if the lining
thickness is less than 2 mm (0.08 in),
have a Yamaha dealer replace the
brake pads as a set.
1. Front brake lever free play
1. Rear brake lever free play
1
ZAUM01071ZAUM0108
1. Lining thickness
1
ZAUM0058
U3C6E1E0.book Page 14 Friday, August 8, 2008 10:09 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-15
6
EAU22500
Rear brake pads
Check each rear brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 2 mm (0.08 in),
have a Yamaha dealer replace the
brake pads as a set.
EAU22580
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:

When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.


Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.


Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Lining thickness
1
ZAUM0278
1. Minimum level mark
11
ZAUM0280
Recommended brake fluid:
DOT 4
U3C6E1E0.book Page 15 Friday, August 8, 2008 10:09 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-16
6
EAUM1360
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the brake
hose replaced every four years or
whenever it is damaged or leaking.
EAU23111
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
EAU23172
Lubricating the front and rear
brake levers The pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic main-
tenance and lubrication chart.
Recommended lubricant:
Silicone greaseZAUM0061
U3C6E1E0.book Page 16 Friday, August 8, 2008 10:09 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-17
6
EAU23192
Checking and lubricating the
centerstand The operation of the centerstand
should be checked before each ride,
and the pivots and metal-to-metal con-
tact surfaces should be lubricated if
necessary.
WARNING
EWA11301
If the centerstand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. Otherwise,
the centerstand could contact the
ground and distract the operator, re-sulting in a possible loss of control.
EAU23272
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.
[EWA10751]
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
1. Centerstand
1
ZAUM0455
Recommended lubricant:
Lithium-soap-based grease
U3C6E1E0.book Page 17 Friday, August 8, 2008 10:09 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-18
6
NOTICE
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-pair it.
EAU45511
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place the vehicle on the center-
stand. WARNING! To avoid inju-
ry, securely support the vehicle
so there is no danger of it falling
over.
[EWA10751]
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
EAU23290
Checking the wheel bearings The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
ZAUM0296
ZAUM0297
U3C6E1E0.book Page 18 Friday, August 8, 2008 10:09 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-19
6
EAUM1403
Battery A poorly maintained battery will corrode
and discharge quickly. The electrolyte
level, battery lead connections and
breather hose routing should be
checked before each ride and at the in-
tervals specified in the periodic mainte-
nance and lubrication chart.
To check the electrolyte level
1. Place the scooter on a level sur-
face and hold it in an upright posi-
tion.
TIPMake sure that the scooter is posi-
tioned straight up when checking theelectrolyte level.
2. Remove panel A. (See page 6-6.)
3. Check the electrolyte level in the
battery.TIPThe electrolyte should be between theminimum and maximum level marks.
4. If the electrolyte is at or below the
minimum level mark, add distilled
water to raise it to the maximum
level mark. NOTICE: Use onlydistilled water, as tap water con-
tains minerals that are harmful
to the battery.
[ECA10611]
WARNING
EWA10760


Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
EXTERNAL: Flush with plenty
of water.
INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
EYES: Flush with water for 15
minutes and seek prompt
medical attention.


Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed
space.
1. Battery
1. Maximum level mark
2. Minimum level mark1
2
+
UPPER
LOWER
ZAUM0106
U3C6E1E0.book Page 19 Friday, August 8, 2008 10:09 AM