maintenance YAMAHA EC-03 2012 User Guide

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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PERIODIC MAINTENANCE AND ADJUSTMENT
8-8
2
3
4
5
6
789
EAU22361
Checking the front and rear
brake shoes Front
Rear The front and rear brake shoes must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart. Each brake is provid-
ed with a wear indicator, which allows
you to check the brake shoe wear with-
out having to disassemble the brake.
To check the brake shoe wear, check
the position of the wear indicator while
applying the brake. If a brake shoe has
worn to the point that the wear indicator
reaches the wear limit line, have a
Yamaha dealer replace the brake
shoes as a set.
EAU23095
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING! Damage to the outer
housing of cables may result in in-
ternal rusting and cause interfer-
ence with cable movement. Replace
damaged cables as soon as possi-
ble to prevent unsafe condi-
tions.
[EWA10711]

1. Brake shoe wear indicator
2. Brake shoe wear limit line
1. Brake shoe wear indicator
2. Brake shoe wear limit line
1
2
1
2
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil
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PERIODIC MAINTENANCE AND ADJUSTMENT
8-9
1
2
3
4
5
6
78
9
EAU43631
Lubricating the front and rear
brake levers Front brake lever
Rear brake lever
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.
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.
Recommended lubricant: Lithium-soap-based grease
Recommended lubricant:Lithium-soap-based grease
1CB-9-EA.book 9 ページ ２０１２年４月１１日　水曜日　午前９時３４分

PERIODIC MAINTENANCE AND ADJUSTMENT
8-10
2
3
4
5
6
789
EAU42081
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
and damage.
To check the operation1. 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.
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.
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PERIODIC MAINTENANCE AND ADJUSTMENT
8-11
1
2
3
4
5
6
78
9
EAU23291
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.
EAU23798
Replacing the headlight bulb This model is equipped with a halogen
bulb headlight. If the headlight bulb
burns out, replace it as follows.NOTICE
ECA10650
Take care not to damage the follow-
ing parts:
Headlight bulb
Do not touch the glass part of
the headlight bulb to keep it free
from oil, otherwise the transpar-
ency of the glass, the luminosity
of the bulb, and the bulb life will
be adversely affected. Thor-
oughly clean off any dirt and fin-
gerprints on the headlight bulb
using a cloth moistened with al-
cohol or thinner.

Headlight lens
Do not affix any type of tinted
film or stickers to the headlight
lens.
Do not use a headlight bulb of awattage higher than specified.1. Remove the headlight unit by re-
moving the screws.
1. Do not touch the glass part of the bulb.
1. Screw
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
8-12
2
3
4
5
6
789
2. Disconnect the headlight coupler,
and then remove the headlight
bulb cover.
3. Unhook the headlight bulb holder, and then remove the burnt-out bulb.
4. Place a new headlight bulb into po- sition, and then secure it with the
bulb holder.
5. Install the bulb cover, and then connect the coupler.
6. Install the headlight unit by install- ing the screws.
7. Have a Yamaha dealer adjust the headlight beam if necessary.
EAU24133
Replacing the ta il/brake light
bulb 1. Remove the tail/brake light lens by
removing the screws.
2. Remove the burnt-out bulb by pushing it in and turning it counter-
clockwise.
1. Screw
1. Headlight coupler
2. Headlight bulb cover
1
1
2
1. Headlight bulb holder
1
1. Tail/brake light lens
2. Screw
1
2
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PERIODIC MAINTENANCE AND ADJUSTMENT
8-13
1
2
3
4
5
6
78
93. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the screws. NOTICE: Do not over-
tighten the screws, otherwise
the lens may break.
[ECA10681]

EAU24204
Replacing a turn signal light
bulb 1. Remove the turn signal light lens
by removing the screw.
2. Remove the burnt-out bulb by pushing it in and turning it counter-
clockwise. 3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the screw. NOTICE: Do not over-
tighten the screw, otherwise the
lens may break.
[ECA11191]

1. Tail/brake light bulb
1
1. Turn signal light lens
2. Screw
1
2
1. Turn signal light bulb
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
8-14
2
3
4
5
6
789
EAU50573
Checking the charging cord
and charging plug 
Check that there is no damage to
the charging cord or charging plug,
and if problem is detected, have a
Yamaha dealer check the vehicle.

Check that there is no dirt or for-
eign material on the charging cord
or charging plug. Wipe off any dirt
with a dry cloth.
WARNING
EWA15791

Do not check or repair the vehi-
cle with the charging plug
plugged in to the outlet. This
could cause an electric shock or short circuit.

Replace the charging cord or
charging plug if damaged. Oth-
erwise, this could cause a fire,electric shock or short circuit.
NOTICE
ECA17102
Make sure that corrosion inhibitors,
solvents or oil do not come in con-
tact with the charging cord or charg-ing plug while checking the vehicle.
1. Tear
1
1. Crack
1. Bend
1
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
8-15
1
2
3
4
5
6
78
9
EAU50184
Troubleshooting If a problem occurs, check the following
before taking the vehicle to a Yamaha
dealer. However, if no electric power is
supplied (nothing appears in the dis-
play), have a Yamaha dealer check the
vehicle.
The vehicle does not enter the
standby mode when the key is
turned to “ON”
Check the following:1. Is the vehicle currently being charged?
The vehicle does not enter the
standby mode when the key is
turned to “ON” during charging.
2. Was the key turned to “ON” while the accelerator grip was being
opened?
If the key is turned to “ON” while
the accelerator grip is opened, the
vehicle does not enter the standby
mode. Close the accelerator grip,
turn the key to “OFF” and then
back to “ON”.
If the vehicle still fails to enter the stand-
by mode, have a Yamaha dealer check the vehicle.
The vehicle does not start off
Is the vehicle in the riding mode? (Does
the operating status indicator “RUN”
appear in the display?)
The vehicle cannot be ridden unless it
is in the riding mode.
After checking the above, try starting off
again by following the procedures de-
scribed on page 7-1 “Preparations for
starting off” and page 7-3 “Starting off”
to restart the vehicle.
If the vehicle still does not start off, have
a Yamaha dealer check it.
The warning mark “ ” appears
Turn the key to “OFF” and then back to
“ON”. If the warning mark “ ” still ap-
pears, have a Yamaha dealer check
the vehicle.
TIPAlthough the warning mark appears,
the vehicle can still be ridden if the op-
erating status indicator “RUN” appearsand the vehicle is in the riding mode.
A light does not come on
Check the following:
1. Is the vehicle currently being charged? Lights do not come on if
the vehicle is being charged.
2. Is the key turned to “ON”? (Does anything appear in the display?)
If nothing appears in the display,
the auto-off function may be acti-
vated. Turn the key to “OFF” and
then back to “ON”.
3. Are all switches working properly?
After checking the above, and a light
does still not come on, proceed with the
following.

If the headlight fails to come on,
the bulb may be burned out. Refer
to page 8-11 for replacement pro-
cedures.

If a tail/brake light or turn signal
light fails to come on, a bulb may
be burned out. Refer to page 8-12
or 8-13 for replacement proce-
dures.
If a light still does not come on, a fuse
may be blown. Have a Yamaha dealer
check the vehicle.
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PERIODIC MAINTENANCE AND ADJUSTMENT
8-16
2
3
4
5
6
789
NOTICE
ECA11982
Do not use a bulb of a wattage other
than specified to avoid causing ex-
tensive damage to the electrical sys-tem and possibly a fire.
The motor stops while riding
Check the following:1. Is the battery sufficiently charged? Check the battery level indicator. If
the remaining charge is insuffi-
cient, charge the battery before
continuing to ride.
2. Is “HEAT” flashing and did “RUN” go off?
The temperature protection func- tion has been activated. Turn the
key to “OFF”, and allow the vehicle
to cool down before continuing to
ride.
After checking the above, if the motor
still does not run, have a Yamaha deal-
er check the vehicle.
WARNING
EWA15631
Before pushing or moving the
EC-03, be sure to turn the key to
“OFF”. The vehicle may suddenly
start to move if the accelerator grip
is turned while the key is turned to“ON”.
The display and headlight go off
when the key is turned to “ON”
Check the following: 1. Has the vehicle been stopped for more than five minutes?
To protect the battery, the EC-03 is
equipped with an auto-off function.
If the vehicle has been stopped for
more than five minutes, the power
is cut to save the battery charge.
2. Is the battery sufficiently charged? If the remaining charge is insuffi- cient, charge the battery before
continuing to ride.
After checking the above, turn the key
to “ON” again. If the display and head-
light do not come on, have a Yamaha
dealer check the vehicle.
WARNING
EWA15631
Before pushing or moving the
EC-03, be sure to turn the key to
“OFF”. The vehicle may suddenly
start to move if the accelerator grip
is turned while the key is turned to“ON”.
The security lock cannot be un-
locked
If an incorrect security number is en-
tered three times in succession, the se-
curity lock cannot be unlocked even if
the correct security number is entered
after that.
Turn the key to “OFF” and then back to
“ON”, then try entering the correct se-
curity number again.
1. Temperature indicator “HEAT”
1
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