check engine light YAMAHA JOG50R 2005 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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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 imba-
lance or instability.
Shifting weights can create a sud-
den imbalance. Make sure that
accessories and cargo are secu-
rely 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
test all other accessories that may be
available, you must personally be res-
ponsible for the proper selection, ins-
tallation 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 “Loa-
ding” when mounting accessories.
Never install accessories or carry
cargo that would impair the per-
formance of your scooter. Care-
fully inspect the accessory befo-
re using it to make sure that it
does not in any way reduce
ground clearance or cornering
clearance, limit suspension tra-
vel, steering travel or control ope-
ration, or obscure lights or reflec-
tors.
• Accessories fitted to the hand-
lebar or the front fork area can
create instability due to impro-
per weight distribution or
aerodynamic 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 aerodyna-
mic effects. Wind may attempt
to lift the scooter, or the scoo-ter may become unstable in
cross winds. These accesso-
ries 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 fre-
edom of movement of the ope-
rator and may limit control abi-
lity, therefore, such
accessories are not recom-
mended.
Use caution when adding electri-
cal accessories. If electrical
accessories 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.
Gasoline 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.
1
tSAFETY INFORMATION
1-3
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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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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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EAU19602
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause
any spark plug to slowly erode, the
spark plug should be removed and
checked in accordance with the
periodic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
To remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as
shown, with the spark plug
wrench included in the owner’s
tool kit.
To check the spark plug
1. Check that the porcelain insula-
tor around the center electrode of
the spark plug is a medium-to-
light tan (the ideal color when the
vehicle is ridden normally).
NOTE:
If the spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnosesuch problems yourself. Instead, have
a Yamaha dealer check the vehicle.
2. Check the spark plug for electro-
de erosion and excessive carbon
or other deposits, and replace it if
necessary.
To install the spark plug
1. Distance between electrodes
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to spe-
cification.2. Clean the surface of the spark
plug gasket and its mating surfa-
ce, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4~1/2 turn past finger tight. Howe-
ver, the spark plug should be tighte-
ned to the specified torque as soon
as possible.
4. Install the spark plug cap.
Tightening torque:
Spark plug:
20 Nm (2,0 m•kgf, 14,6 ft•lbf)
Spark plug gap:
0,6 ~ 0,7 mm (0,24 ~ 0,27in)
Specified spark plug:
BR8HS/NGK
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
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EAUS1080
To check the coolant level
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion.
NOTE:
The coolant level must be chec-
ked on a cold engine since the
level varies with engine tempera-
ture.
Make sure that the vehicle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
1. Coolant level gauge window
2. Check the coolant level through
the check window.
NOTE:
The coolant should be between the
minimum and maximum level marks.
1. Coolant reservoir
3. If the coolant is at or below the
minimum level mark, remove the
front cowling by removing the
screws.
4. Open the reservoir cap, and then
add coolant to the maximum
level mark.
ECA10470
CAUTION
If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
If water has been used instead
of coolant, replace it with coo-
lant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the coo-
ling system will not be protec-
ted against frost and corrosion.
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possi-
ble, otherwise the effective-
ness of the coolant will be
reduced.
5. Close the reservoir cap, and then
install the front cowling by insta-
lling the screws.Coolant reservoir capacity:
0,380 L (0,00103 Imp.qt)
kbajdzc4050
30
10 2060
70
80
0:
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
11
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22-Stroke engine oil .....................................1-1
AAcceleration and deceleration ...................2-1
Adjusting the autolube pump ....................2-1
Adjusting the carburetor ............................2-2
Adjusting the front brake lever free play....2-3
Adjusting the rear brake lever free play .....3-1
Adjusting the throttle cable free play .........3-1
BBattery........................................................3-1
Braking .......................................................3-2
CCare............................................................3-3
Changing the brake fluid............................3-3
Checking and lubricating the cables .........3-3
Checking and lubricating the centerstand.3-4
Checking and lubricating the throttle
grip and cable ..........................................3-4
Checking the front brake fluid level ...........3-4
Checking the front fork ..............................3-5
Checking the spark plug ............................3-6
Checking the steering ................................3-6
Checking the wheel bearings ....................3-6
Cheking the front brake pads and
rear brake shoes ......................................4-1
Cleaning the air filter element ....................4-2
Clock ..........................................................5-1
Controls and instruments ..........................5-1
Coolant (only for liquid-cooled models) ...5-2
EEngine break-in ..........................................5-2
FFinal transmission oil .................................5-2Front brake lever ........................................6-1
Fuel and 2 stroke engine oil tank caps......6-2
Fuel gauge .................................................6-5
HHandlebar switches ...................................6-6
IIndicator lights ...........................................6-6
KKickstarter ..................................................6-8
LLeft view .....................................................6-9
Lubricating the front and rear brake
levers .......................................................6-9
M
Main switch/steering lock ..........................6-9
PParking .....................................................6-11
Periodic maintenance and lubrication
chart .......................................................6-12
Pre-operation check list ...........................6-13
RRear brake lever .......................................6-14
Replacing a turn signal light bulb or
the tail/brake light bulb ..........................6-14
Replacing the fuse ...................................6-14
Replacing the headlight bulb or a
front turn signal light bulb .....................6-14
Replacing the license plate light bulb......6-15
Right view ................................................6-15
SSeat ..........................................................6-16
Speedometer unit ....................................6-17
Starting a cold engine ..............................6-18
Starting off ...............................................6-19Storage compartment ..............................6-20
Storage compartment ................................7-1
TTires ...........................................................7-1
To check the coolant level .........................7-3
Troubleshooting .........................................8-1
Troubleshooting chart ................................9-1
INDEX
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