maintenance YAMAHA EC-03 2011 Owners Manual

TABLE OF CONTENTSSAFETY INFORMATION .................. 1-1
Further safe-riding points ................ 1-4
Charging the battery safely ............. 1-5
DESCRIPTION .................................. 2-1
Left view .......................................... 2-1
Right view ........................................ 2-2
Controls and instruments................. 2-3
EC-03 FEATURES............................. 3-1
Features ......................................... 3-1
Standard mode/power mode .......... 3-1
Traveling distance .......................... 3-2
Effective use of the battery ............. 3-3
Battery level .................................... 3-4
INSTRUMENT AND CONTROL
FUNCTIONS....................................... 4-1
Beeper ............................................ 4-1
Main switch/steering lock ................ 4-1
Multi-function display ...................... 4-2
Using the security lock .................... 4-7
Handlebar switches ...................... 4-11
Front brake lever .......................... 4-11
Rear brake lever ........................... 4-11
Seat .............................................. 4-12
Helmet holder ............................... 4-12
Luggage hook ............................... 4-13
Grab bar ....................................... 4-13FOR YOUR SAFETY –
PRE-OPERATION CHECKS............. 5-1
CHARGING THE BATTERY.............. 6-1
Battery charging location ................ 6-1
Charging procedure ....................... 6-3
Charging time ................................. 6-8
Display of charging progress
status .......................................... 6-9
About the battery ............................ 6-9
OPERATION AND IMPORTANT
RIDING POINTS................................. 7-1
Preparations for starting off ............ 7-1
Starting off ...................................... 7-3
Acceleration and deceleration ........ 7-4
Braking ........................................... 7-5
Parking ........................................... 7-5
PERIODIC MAINTENANCE AND
ADJUSTMENT................................... 8-1
General maintenance and
lubrication chart .......................... 8-2
Checking for irregular motor
sounds ........................................ 8-4
Checking the accelerator grip ........ 8-4
Tires ............................................... 8-5
Cast wheels .................................... 8-6
Adjusting the front and rear
brake lever free play ................... 8-6Checking the front and rear brake
shoes ........................................... 8-8
Checking and lubricating the
cables .......................................... 8-8
Lubricating the front and rear
brake levers ................................. 8-9
Checking and lubricating the
centerstand .................................. 8-9
Checking the front fork .................. 8-10
Checking the steering ................... 8-10
Checking the wheel bearings ........ 8-11
Replacing the headlight bulb ........ 8-11
Replacing the tail/brake light
bulb ............................................ 8-12
Replacing a turn signal light
bulb ............................................ 8-13
Checking the charging cord and
charging plug ............................. 8-14
Troubleshooting ............................ 8-15
SCOOTER CARE AND STORAGE.... 9-1
Matte color caution ......................... 9-1
Care ................................................ 9-1
Storage ........................................... 9-3
SPECIFICATIONS ........................... 10-1
CONSUMER INFORMATION........... 11-1
Identification numbers ................... 11-11CB-9-E0.book 1 ページ ２０１０年１０月１５日　金曜日　午前１０時１９分

INSTRUMENT AND CONTROL FUNCTIONS
4-4
2
345
6
7
8
9
TIPWhen the vehicle is in the riding mode,
the beeper sounds. The beeper stops
when either brake lever is squeezed orthe vehicle starts moving.
Control buttons
Button 1 “POWER”
Button 2 “SET”
Button 3 “SELECT”
The following operations and settings
are made using these buttons.
Changing from the standby mode
to the riding mode

Switching between the standard
mode and the power mode

Switching between the odometer
and the tripmeter

Resetting the tripmeter

Registering or changing the secu-
rity number

Locking and unlocking the security
lock
Speedometer
The speedometer shows the riding
speed.Tripmeter “Trip”
The tripmeter shows the distance trav-
eled since it was last set to zero. To re-
set the tripmeter, push and hold button
3 “SELECT” for a few seconds until
“0.0” is displayed.
Odometer “Odo”
Push button 3 “SELECT” for at least
one second to switch the display to the
odometer.
The odometer shows the total distance
traveled. Use the odometer as a refer-
ence for the intervals between perform-
ing periodic maintenance.
Push button 3 for at least one second to
switch the display to the tripmeter.
Temperature warning display
“HEAT”/“COOL”
The EC-03 is equipped with a tempera-
ture protection function to protect the
battery and control unit.
If a problem is detected, the tripmeter/
odometer display is canceled and
“COOL” or “HEAT” flash.

When the temperature of the bat-
tery or control unit exceeds a spec-
ified temperature, “HEAT” flashes.

When the temperature of the bat-
tery falls below a specified temper-
ature, “COOL” flashes.
TIP
When the temperature of the bat-
tery exceeds a specified tempera-
ture, “HEAT” flashes and the
driving power is reduced to limit
the electric output from the battery,
but this is normal.

When the temperature of the bat-
tery falls below a specified temper-
ature, “COOL” flashes and the
driving power is reduced to limit
the electric output from the battery,
but this is normal.

If the vehicle is ridden for an ex-
tended period in high tempera-
tures, “HEAT” may flash and the
riding speed may be reduced.

If the vehicle is ridden after it has
been left in a hot place or under di-
rect sunlight, “HEAT” may flash
and the riding speed may be re-
duced.

If the vehicle is ridden after it has
been left in an excessively cold
place (less than 0 C), “COOL”
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5-1
2
3
456
7
8
9
FOR YOUR SAFETY – PRE-OPERATION CHECKS
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided inthis manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Front brake• Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary.8-6, 8-8
Rear brake• Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary.8-6, 8-8
Control cables• Make sure that operation is smooth.
• Lubricate if necessary.8-8
Wheels and tires• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.8-5, 8-6
Brake levers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.8-9
Centerstand• Make sure that operation is smooth.
• Lubricate pivot if necessary.8-9
Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.—
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8-1
1
2
3
4
5
6
78
9
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU50130
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obligation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING
EWA10321
Failure to properly maintain the ve-
hicle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer performservice.
WARNING
EWA15840
Turn the key to “OFF” when per-
forming maintenance unless other-
wise specified. A running motor has
moving parts that can catch on body
parts or clothing and electrical partsthat can cause shocks or fires.
WARNING
EWA15830
This scooter is designed for use onpaved roads only.
WARNING
EWA15460
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool beforetouching them.
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PERIODIC MAINTENANCE AND ADJUSTMENT
8-2
2
3
4
5
6
789
EAU50610
TIP
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.

From 30000 km, repeat the maintenance intervals starting from 6000 km.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
EAU50620
General maintenance and lubrication chart NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK
1000 km 6000 km 12000 km 18000 km 24000 km
1*Front brake• Check operation and adjust
brake lever free play.
• Replace brake shoes. Whenever worn to the limit
2*Rear brake• Check operation and adjust
brake lever free play.
• Replace brake shoes. Whenever worn to the limit
3*Wheels• Check runout and for damage.
4*Tires• Check tread depth and for
damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
5*Wheel bearings• Check bearing for looseness or
damage.
6*Steering bearings• Check bearing play and steering
for roughness.
• Lubricate with
lithium-soap-based grease.Every 24000 km
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PERIODIC MAINTENANCE AND ADJUSTMENT
8-3
1
2
3
4
5
6
78
9
7*Chassis fasteners• Make sure that all nuts, bolts
and screws are properly
tightened.
8Front brake lever
pivot shaft• Lubricate with
lithium-soap-based grease.
9Rear brake lever
pivot shaft• Lubricate with
lithium-soap-based grease.
10Centerstand• Check operation.
• Lubricate.
11 *Front fork• Check operation and for oil
leakage.
12 *Shock absorber
assembly• Check operation and shock
absorber for oil leakage.
13 *Front and rear
brake switches• Check operation.
14Moving parts and
cables• Lubricate.
15 *Accelerator grip• Check operation.
• Correct if necessary.
16 *Lights, signals and
switches• Check operation.
• Adjust headlight beam.
17 *Motor noise• Check for irregular noise coming
from the motor.
• Correct if necessary.
18 *Charging cord and
plug• Check condition and for
damage.
• Replace if necessary. NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK
1000 km 6000 km 12000 km 18000 km 24000 km
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PERIODIC MAINTENANCE AND ADJUSTMENT
8-4
2
3
4
5
6
789
EAU50143
Checking for irregular motor
sounds Check the motor for irregular sounds.TIPThe motor cannot be revved beyond a
certain motor speed by turning the ac-
celerator grip when the vehicle is on thecenterstand.
EAU50154
Checking the accelerator grip Before checking the accelerator grip,
check the following points.
Make sure that the key is in the
“OFF” position. Turn the accelera-
tor grip slowly and check that it
moves smoothly, and returns
smoothly when released.

Check for any signs of deteriora-
tion or damage around the accel-
erator grip. Also check the
accelerator grip holder mounting
bolts for tightness.

When washing the vehicle, avoid
spraying the area around the ac-
celerator grip with water. If the
area around the accelerator grip is
particularly dirty, use a well-wrung
damp cloth to clean.
WARNING
EWA15671
If a problem is found in accelerator
grip operation, do not operate the
vehicle. Have the vehicle inspected
by a Yamaha dealer. Continuing to
use the vehicle with a problem in-
creases the possibility of an acci-dent or equipment damage.
1. Squeeze the rear brake lever with
your left hand.
2. Turn the key to “ON”.
3. Cancel the standby mode by
pressing one of the control but-
tons. (See page 4-3.)
4. Make sure that the operating sta-
tus indicator “RUN” is displayed,
and that the vehicle is in the riding
mode. (See page 7-1 for more in-
formation about “Preparations for
starting off” and “Starting off”.)
5. Check that the accelerator grip
and motor operate smoothly when
the vehicle is accelerated by grad-
ually turning the accelerator grip
while riding the vehicle. If there is a
problem, have a Yamaha dealer
check the vehicle.
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PERIODIC MAINTENANCE AND ADJUSTMENT
8-5
1
2
3
4
5
6
78
9
EAU50673
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
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.
TIPThe tire tread depth limits may differ
from country to country. Always complywith the local regulations.Tire information
This vehicle is equipped with cast
wheels and tube tires.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
WARNING
EWA10471

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-
Tire air pressure (measured on cold
tires):
Front:
200 kPa (2.00 kgf/cm
2, 29 psi)
Rear:
250 kPa (2.50 kgf/cm2, 36 psi)
Maximum load*:
87 kg (192 lb)
* Total weight of rider, cargo and ac-
cessories
1. Tire tread depth
2. Tire sidewallMinimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
12
Front tire:
Size:
60/100-12 36J
Manufacturer/model:
INOUE RUBBER/MB80
Rear tire:
Size:
60/100-12 36J
Manufacturer/model:
INOUE RUBBER/MB80
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PERIODIC MAINTENANCE AND ADJUSTMENT
8-6
2
3
4
5
6
789 edge and experience to do so.

Ride at moderate speeds after
changing a tire since the tire
surface must first be “broken
in” for it to develop its optimalcharacteristics.
EAU22002
Cast wheels
WARNING
EWA10610
The wheels on this model are not de-
signed for use with tubeless tires.
Do not attempt to use tubeless tireson this model.
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, warpage or
damage before each ride. If any
damage is found, have a Yamaha
dealer replace 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.
EAU22152
Adjusting the front and rear
brake lever free play The front and rear brake lever free play
should be measured at the positions as
shown.
Front1. Front brake lever
2. Brake lever free play
1
2
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PERIODIC MAINTENANCE AND ADJUSTMENT
8-7
1
2
3
4
5
6
78
9Rear
Periodically check the front and rear
brake lever free play and, if necessary,
adjust them as follows.
To increase the brake lever free play,
turn the adjusting nut at the brake shoe
plate in direction (a). To decrease the
brake lever free play, turn the adjusting
nut in direction (b).Front
Rear
WARNING
EWA10650
If proper adjustment cannot be ob-
tained as described, have a Yamaha
dealer make this adjustment.
1. Rear brake lever
2. Brake lever free playFront brake lever free play:
10.0–20.0 mm (0.39–0.79 in)
Rear brake lever free play:
10.0–20.0 mm (0.39–0.79 in)
1
2
1. Front brake lever free play adjusting nut
1. Rear brake lever free play adjusting nut
(a)
(b) 1
1
(a) (b)
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