oil level YAMAHA JOG50R 2004 Owners Manual

SAFETY INFORMATION.....................1-1
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 ..................................3-1
Speedometer unit .............................3-2
Fuel gauge ........................................3-3
Clock .................................................3-3
Handlebar switches ..........................3-3
Front brake lever...............................3-4
Rear brake lever................................3-4
Fuel and 2 stroke engine oil
tank caps .......................................3-4
2-Stroke engine oil ...........................3-5
Kickstarter.........................................3-6
Seat...................................................3-6
Storage compartment.......................3-6
PRE-OPERATION CHECKS...............4-1
Pre-operation check list....................4-2
OPERATION AND IMPORTANT RIDING
POINTS................................................5-1
Starting a cold engine ......................5-1
Starting off ........................................5-1Acceleration and deceleration ..........5-2
Braking..............................................5-2
Engine break-in.................................5-2
Parking ..............................................5-2
PERIODIC MAINTENANCE AND
MINOR REPAIRS................................6-1
Periodic maintenance and
lubrication chart ............................6-2
Checking the spark plug ..................6-5
Final transmission oil ........................6-6
Coolant (only for liquid-cooled
models) ..........................................6-6
To check the coolant level ................6-7
Cleaning the air filter element ...........6-8
Adjusting the carburetor ...................6-9
Adjusting the throttle cable
free play .........................................6-9
Tires ..................................................6-9
Adjusting the front brake lever
free play .......................................6-11
Adjusting the rear brake lever
free play .......................................6-11
Cheking the front brake pads
and rear brake shoes ..................6-12
Checking the front brake fluid
level .............................................6-13
Changing the brake fluid ................6-13
Checking and lubricating the
cables ..........................................6-13Checking and lubricating the
throttle grip and cable .................6-14
Adjusting the autolube pump .........6-14
Lubricating the front and rear
brake levers .................................6-14
Checking and lubricating the
centerstand .................................6-14
Checking the front fork ...................6-15
Checking the steering.....................6-15
Checking the wheel bearings .........6-15
Replacing the headlight bulb or
a front turn signal light bulb ........6-16
Replacing a turn signal light bulb
or the tail/brake light bulb ...........6-16
Replacing the license plate light
bulb .............................................6-17
Battery ............................................6-17
Replacing the fuse ..........................6-18
Troubleshooting ..............................6-19
Troubleshooting chart .....................6-20
SCOOTER CARE AND STORAGE.....7-1
Care ..................................................7-1
Storage compartment.......................7-3
SPECIFICATIONS...............................8-1
CONSUMER INFORMATION.............9-1
TABLE OF CONTENTS
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EAU10430
Controls and instruments
DESCRIPTION
2-3
2
17. Rear brake lever (page 6-11)
18. Left handlebar switch (page 3-3)
19. Speedometer (page 3-2)
20. Turn signal indicator light (page 3-1)
21. High beam light (page 3-1)
22. Oil level warning light (page 3-1)
23. Coolant temperature warning light (page 3-1)
24. "TRIP" button (page 3-2)25. Fuel gauge (page 3-3)
26. Front brake lever (page 3-4 )
27. Right handlebar switch (page 3-3)
28. Turn signal switch (page 3-3)
29. Horn switch (page 3-3)
30. Main switch (page 3-1)
31. Coolant level gauge window (page 6-7)
kb
ajd
z
c4050
30
10 2060
70
80
0
y
17
2928
31 30 2726
20 21
25 23 19 20
18
2422
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EAU10460
Main switch/steering lock
The main switch/steering lock con-
trols the ignition and lighting systems,
and is used to lock the steering. The
various positions are described
below.
EAU10630
ON
All electrical systems are supplied
with power, and the engine can be
started. The key cannot be removed.
EAU10660
OFF
All electrical systems are off. The key
can be removed.
EAU10670
*
The 2-stroke engine oil level warning
light should come on. (See page 3-1.)
EAU10680
LOCK
The steering is locked, and all electri-
cal systems are off. The key can be
removed.
T
o lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF”
position, and then turn it to
“LOCK” while still pushing it.
3. Remove the key.
T
o unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
EWA10060
s s
WARNING
Never turn the key to “OFF” or
“LOCK” while the vehicle is
moving, otherwise the electrical
systems will be switched off, which
may result in loss of control or an
accident. Make sure that the vehi-
cle is stopped before turning the
key to “OFF” or “LOCK”.
EAU10980
Indicator lights
1. Turn signal indicator lights “b”
2. High beam indicator light “j”
3. Oil level warning light “z”
4. Coolant temperature warning light “y”
j
d
z
c4050
30
10 2060
70
80
0
y
00000.0
23:08TOTALExF
3
INSTRUMENT AND CONTROL FUNCTIONS
3-1
2 1
4
3
1
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EAU11030
Turn signal indicator lights “c” and
“d”
The corresponding indicator light flas-
hes when the turn signal switch is
pushed to the left or right.
EAU11080
High beam indicator light “j”
This indicator light comes on when
the high beam of the headlight is swit-
ched on.
EAU11130
2-stroke engine oil level warning
light “z”
This warning light comes on when the
2-stroke engine oil level is low.
The electrical circuit of the warning
light can be checked according to the
following procedure.
1. Turn the key to “ON”.
2. Shift the transmission into the
neutral position.
3. If the warning light does not
come on, have a Yamaha dealer
check the electrical circuit.
ECA11570
CAUTION
Do not operate the motorcycle until
you know that the 2-stroke engine
oil level is sufficient.
NOTE:
Even if the 2-stroke engine oil level is
sufficient, the warning light may flic-
ker when riding on a slope or during
sudden acceleration or deceleration,
but this is not a malfunction.
EAU11430
Coolant temperature warning light
“y”
This warning light comes on when the
engine overheats. When this occurs,
stop the engine immediately and
allow the engine to cool.
ECA10020
CAUTION
Do not operate the engine if it is
overheated.
EAUM1090
Speedometer unit
1. Speedometer unit
2. Fuel gauge
3. Clock
4. Odometer (TOTAL/TRIP)
5. “TRIP” button
The speedometer unit is equipped
with a speedometer, an odometer and
a tripmeter. The speedometer shows
riding speed. The odometer shows
the total distance traveled. The trip-
meter shows the distance traveled
since it was last set to zero.
Pushing the reset button switches the
display between the odometer mode
“TOTAL” and the tripmeter mode
“TRIP”. To reset the tripmeter, enter
the “TRIP” mode, and then hold down
j
d
z
c4050
30
10 2060
70
80
0
y
00000.0
23:08TOTALExF
3
INSTRUMENT AND CONTROL FUNCTIONS
3-2
14
3
2 5
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2-stroke engine oil tank cap
To remove the 2-stroke engine oil tank
cap, pull it off.
To install the 2-stroke engine oil tank
cap, push it into the oil tank opening.
EWA10140
s s
WARNING
Make sure that the fuel and 2-stro-
ke engine oil tank caps are properly
installed before riding the scooter.
EAU13220
Fuel
1. Refill pipe
2. Fuel level
Make sure that there is sufficient fuel
in the tank. When refueling, be sure to
insert the pump nozzle into the fuel
tank filler hole and to fill the tank to
the bottom of the filler tube as shown.
EWA10880
s s
WARNING
Do not overfill the fuel tank,
otherwise it may overflow
when the fuel warms up and
expands.
Avoid spilling fuel on the hot
engine.
ECA10070
CAUTION
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfa-
ces or plastic parts.
EAU13270
Your Yamaha engine has been desig-
ned to use regular unleaded gasoline
with a research octane number of 91
or higher. If knocking (or pinging)occurs, use a gasoline of a different
brand or premium unleaded fuel. Use
of unleaded fuel will extend spark
plug life and reduce maintenance
costs.
EAU13460
2-stroke engine oil
Make sure that there is sufficient oil in
the 2-stroke engine oil tank. Add the
recommended 2-stroke engine oil if
necessary.
NOTE:
Make sure that the 2-stroke engine oil
tank cap is properly installed.
Recommended oil:
Yamalube 2 or equivalent 2-stroke
engine oil (JASO grade “FC”, or
ISO grades “EG-C” or “EG-D”)
Oil quantity:
1,4L (0,31 US qt)(1,23 Imp.qt)Recommended fuel:
REGULAR UNLEADED GASOLINE
ONLY
Fuel tank capacity:
5,5L (1,21 US gal) (4,8Imp.gal)
Fuel reserve amount:
1,9L(0,42US gal) (1,67Imp.gal)
3
INSTRUMENT AND CONTROL FUNCTIONS
3-5
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EAU15603
Pre-operation check list
PRE-OPERATION CHECKS
4-2
4
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
Fuel• Refuel if necessary. 3-3, 3-4
• Check fuel line for leakage.
• Check oil level in oil tank.
2-stroke engine oil• If necessary, add recommended oil to specified level. 3-4, 3-5
• Check vehicle for oil leakage.
Transmission oil• Check oil level in transmission case.
• If necessary, add recommended oil to specified level.6-6
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Front brake• Replace if necessary. 6-11, 6-12, 6-13, 3-4
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
Rear brake• Lubricate cable if necessary.
3-4, 6-11, 6-12
• Check lever free play.
• Adjust if necessary.
• Make sure that operation is smooth.
Throttle grip• Check cable free play.
6-9, 6-14
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.
• Check for damage.
Wheels and tires• Check tire condition and tread depth.
6-9, 6-15
• Check air pressure.
• Correct if necessary.
Brake levers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.3-4, 6-11, 6-14
Centerstand• Make sure that operation is smooth.
• Lubricate pivot if necessary.6-14
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EAU15980
EWA10870
s s
WARNING
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or func-
tion that you do not thoroughly
understand.
Never start the engine or ope-
rate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of cons-
ciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
For safety, always start the
engine with the centerstand
down.
EAU16560
Starting a cold engineECA10250
CAUTION
See page 5-2 for engine break-in
instructions prior to operating the
vehicle for the first time.
1. Turn the key to “*”, and when the
oil level warning light comes on,
turn it to “ON”.
ECA10240
CAUTION
If the oil level warning light does
not come on, have a Yamaha dealer
check the electrical circuit.
2. Close the throttle completely.
3. While applying the front or rear
brake, start the engine by pus-
hing the start switch or by pus-
hing 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 oneattempt. If the engine does not start
with the starter motor, try using the
kickstarter.
ECA11040
CAUTION
For maximum engine life, never
accelerate hard when the engine is
cold!
EAU16760
Starting off
NOTE:
Before starting off, allow the engine to
warm 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 centers-
tand.
2. Sit astride the seat, and then
adjust 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.
5
OPERATION AND IMPORTANT RIDING POINTS
5-1
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ODOMETER READING (x 1000 Km) ANNUAL
NOITEM CHEK OR MAINTENANCE JOB 1 6 12 18 24CHECK
9*Wheel bearings• Check bearing for looseness or damage.√√√√
10 *Steering bearings• Check bearing play and steering for roughness.√√ √ √√• Lubricate with lithium-soap-based grease. Every 24000 km
11 *Chassis fasteners• Make sure that all nuts, bolts and screws are
properly tightened.√√√√ √
12Centerstand• Check operation.
• Lubricate.√√√√ √
13 *Front fork• Check operation and for oil leakage.√√√√
14 *Shock absorber
• Check operation and shock absorber for oil leakage.√√√√
assembly
15 *Carburetor• Adjust engine idling speed.√√ √ √√ √
16 *Autolube pump• Check operation.
• Bleed if necessary.√√√√
17 *Cooling system• Check coolant level and vehicle for coolant leakage.√√√√ √• Change. Every 3 years
18Final transmission • Check vehicle for oil leakage.√√ √oil
• Change.√√√
19 *V-belt• Replace. Every 12000 km
20 *Front and rear brake
• Check operation.√√ √ √√ √
switches
21Moving parts and
• Lubricate.√√√√ √
cables
22 *Lights, signals • Check operation.
and switches• Adjust headlight beam.√√ √ √√ √
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
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EAU20060
Final transmission oil
1. Oil filler bolt
The final transmission case must be
checked for oil leakage before each
ride. If any leakage is found, have a
Yamaha dealer check and repair the
scooter. In addition, the final trans-
mission oil must be changed as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Start the engine, warm it up by
riding the scooter for several
minutes, and then stop the engi-
ne.
1. Drain plug
2. Place the scooter on the centers-
tand.
3. Place an oil pan under the final
transmission case to collect the
used oil.
4. Remove the oil filler cap and
drain bolt to drain the oil from the
final transmission case.
5. Install the final transmission oil
drain bolt, and then tighten it to
the specified torque.
6. Add the specified amount of the
recommended final transmissionoil, and then install and tighten
the oil filler cap.
EWA11310
s s
WARNING
Make sure that no foreign
material enters the final trans-
mission case.
Make sure that no oil gets on
the tire or wheel.
7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
EAUS1200
Coolant (only for liquid-
cooled models)
The coolant level should be checked
before each ride. In addition, the coo-
lant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended final transmission
oil:
SAE30 motor oil.
Oil quantity:
0,11 L (0,0003 Imp.qt)
Tightening torque:
Final transmission oil drain bolt:
18 Nm (1,8 m•kgf, 13,2 ft•lbf)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
11
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EAU32343
Checking the front brake
fluid level
1. Minimum level
Insufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake
fluid is above the minimum level mark
and replenish if necessary. A low bra-
ke 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
master cylinder is level by turning
the handlebars.
Use only the recommended qua-
lity brake fluid, otherwise the rub-
ber seals may deteriorate, cau-
sing leakage and poor braking
performance.
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performan-
ce.
Be careful that water does not
enter the master cylinder when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
Brake fluid may deteriorate pain-
ted surfaces or plastic parts.
Always clean up spilled fluid
immediately.
As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if
the brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
EAU22720
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addi-
tion, have the oil seals of the brake
master cylinder and caliper as well as
the brake hose replaced at the inter-
vals listed below or whenever they are
damaged or leaking.
Oil seals: Replace every two
years.
Brake hose: Replace every four
years.
EAU23100
Checking and lubricating the
cables
The operation of all control cables
and the condition of the cables
should be checked before each ride,
Recommended brake fluid:
DOT 4
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
MIN
1
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