engine YAMAHA VERSITY 300 2004 User Guide

INSTRUMENT AND CONTROL FUNCTIONS
3
1. Auxiliary DC jack
EAUM0102*
Auxiliary DC jack
This scooter is equipped with an
auxiliary DC jack in the storage
compartment A.
12-V accessories connected to the
auxiliary jack can be used when the key
is in the "
" position and should only
be used when the engine is running.
EC000028*
The accessories connected to the
auxiliary DC jack should not be used
with the engine turned off, and their
combined load must never exceed
2.5 A or 30 W, otherwise the battery
may discharge.
To use the auxiliary DC jack
1. Turn the key to "
".
2. Remove the dust cap from the
receptacle.
3. Insert the accessory plug into the
receptacle.
4. Turn the key to "
", and then start
the engine. (See page 5-1 for
details.)
5. When the accessory jack is not
being used, make sure that the
dust cap is installed onto the
receptacle for protection.
CAUTION:
12V
1
ZAUM0417
3-18

PRE-OPERATION CHECKS
4The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or
loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual
inspection, to check the following points before each ride.
EAU03439
Pre-operation check list
ITEM CHECKS PAGE
•Check fuel level in fuel tank.
Fuel•Refuel if necessary. 3-3 — 3-4, 3-10 — 3-11
•Check fuel line for leakage.
•Check oil level in engine.
Engine oil•If necessary, add recommended oil to specified level. 6-13 — 6-15
•Check vehicle for oil leakage.
Final transmission oil•Check vehicle for oil leakage. 6-16
•Check coolant level in reservoir.
Coolant•If necessary, add recommended coolant to specified level. 6-17
•Check cooling system for leakage.
•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
Front brake•Check fluid level in reservoir. 3-9, 6-23 — 6-25
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.
•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
Rear brake•Check fluid level in reservoir. 3-9, 6-23 — 6-25
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.
4-1

EAU00372
OPERATION AND IMPORTANT RIDING POINTS
Starting the engine .............................................................................. 5-1
Starting off ........................................................................................... 5-2
Acceleration and deceleration ............................................................. 5-3
Braking ................................................................................................ 5-3
Tips for reducing fuel consumption ..................................................... 5-4
Engine break-in ................................................................................... 5-4
Parking ................................................................................................ 5-5
5

OPERATION AND IMPORTANT RIDING POINTS
5
EAU01118
EW000129
•Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or
function that you do not
thoroughly understand.
•Never start the engine or
operate it in a closed area for
any length of time. Exhaust fu-
mes are poisonous, and
inhaling them can cause loss of
consciousness and death
within a short time. Always
make sure that there is
adequate ventilation.
•For safety, always start the
engine with the centerstand
down.
WARNING
EAU03843
Starting the engine
See page 5-4 for engine break-in ins-
tructions prior to operating the
vehicle for the first time.
In order for the ignition circuit cut-off
system to enable starting, the sidestand
must be up.
EW000054
•Before starting the engine,
check the function of the igni-
tion circuit cut-off system
according to the procedure
described on page 3-16.
•Never ride with the sidestand
down.1. Turn the key to "
" and make
sure that the engine stop switch
is set to "
".
2. Close the throttle completely.
3. Start the engine by pushing the
start switch while applying the
front or rear brake.
CAUTION:
WARNING
1234
ZAUM0418
1. Rear brake lever
2. Engine stop switch
3. Start switch
4. Front brake lever
5-1

OPERATION AND IMPORTANT RIDING POINTS
5
NOTE :
If the engine does not start, release the
start 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 10 seconds on any
one attempt. If the engine does not
start, try with the throttle open 1/8 turn.
ECA00045
For maximum engine life, never
accelerate hard when the engine is
cold!
CAUTION:
1
ZAUM0419
1. Grab bar
EAU00433
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
centerstand.
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.
5-2

OPERATION AND IMPORTANT RIDING POINTS
5
EAU04755
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:
•Avoid high engine speeds during
acceleration.
•Avoid high engine speeds with no
load on the engine.
•Turn the engine off instead of
letting it idle for an extended
length of time (e.g., in traffic jams,
at traffic lights or at railroad
crossings).
EAU01128
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1,600 km. For this
reason, you should read the following
material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,600 km. The various parts in the
engine wear and polish themselves to
the correct operating clearances.
During this period, prolonged full-
throttle operation or any condition that
might result in engine overheating must
be avoided.
EAU03845*
0 — 1,000 km
Avoid prolonged operation above 1/3
throttle.
1,000 — 1,600 km
Avoid prolonged operation above 1/2
throttle.
ECA00138
After 1,000 km of operation, be sure
to replace the engine oil and final
transmission oil.
1,600 km and beyond
The vehicle can now be operated
normally.
EC000049
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
CAUTION:
CAUTION:
5-4

OPERATION AND IMPORTANT RIDING POINTS
5
EAU00461
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EW000058
•Since the engine and exhaust
system can become very hot,
park in a place where
pedestrians or children are not
likely to touch them.
•Do not park on a slope or on
soft ground, otherwise the
scooter may overturn.
EC000062
Never park in an area where there
are fire hazards such as grass or
other flammable materials.
WARNING
CAUTION:
5-5

EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit ........................................................ 6-1
Periodic maintenance and lubrication chart ............ 6-2
Removing and installing cowlings and panels ........ 6-5
Checking the spark plug ....................................... 6-11
Engine oil .............................................................. 6-13
Final transmission oil ............................................ 6-16
Coolant .................................................................. 6-17
Air filter and the V-belt case air filter elements ...... 6-18
Adjusting the carburetor ........................................ 6-20
Adjusting the throttle cable free play ..................... 6-20
Adjusting the valve clearance ............................... 6-21
Tires ...................................................................... 6-21
Cast wheels .......................................................... 6-23
Adjusting the front and rear brake lever
free play ................................................................ 6-23
Checking the front and rear brake pads ................ 6-24
Checking the brake fluid level ............................... 6-24
Changing the brake fluid ....................................... 6-25Checking and lubricating the cables ..................... 6-26
Checking and lubricating the throttle grip
and cables ............................................................. 6-26
Lubricating the front and rear brake levers ........... 6-26
Checking and lubricating the centerstand
and sidestand ........................................................ 6-27
Checking the front fork .......................................... 6-27
Checking the steering ........................................... 6-28
Checking the wheel bearings ................................ 6-29
Battery ................................................................... 6-29
Replacing the fuses .............................................. 6-30
Replacing a headlight bulb .................................... 6-32
Replacing a front turn signal light bulb .................. 6-34
Replacing tail/brake light bulb
or rear turn signal light bulb .................................. 6-34
Replacing the license plate light bulb .................... 6-35
Troubleshooting ..................................................... 6-35
Troubleshooting charts .......................................... 6-36
6

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of ins-
pection, adjustment, and lubrication are
explained on the following pages.
The intervals given in the periodic main-
tenance and lubrication chart should be
simply considered as a general guide
under normal riding conditions. However,
DEPENDING ON THE WEATHER,
TERRAIN, GEOGRAPHICAL LOCA-
TION, AND INDIVIDUAL USE, THE
MAINTENANCE INTERVALS MAY
NEED TO BE SHORTENED.
EW000060
If you are not familiar with scooter
maintenance work, have a Yamaha
dealer do it for you.
WARNING
EAU00466
EW000061
This scooter is designed for use on
paved roads only. If this scooter is
operated in abnormally dusty,
muddy or wet conditions, the air filter
element should be cleaned or
replaced more frequently, otherwise
rapid engine wear may result.
Consult a Yamaha dealer for proper
maintenance intervals.
WARNING
EAUT0027*
Owner's tool kit
The owner's tool kit is located inside the
front storage compartment A. (See
page 3-12 for front storage
compartment opening procedures.)
The service information included in this
manual and the tools provided in the
owner's tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs.
However, additional tools such as a
torque wrench may be necessary to
perform certain maintenance work
correctly.
NOTE :
If you do not have the tools or
experience required for a particular job,
have a Yamaha dealer perform it for you.
EW000063
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle unsafe
for use. Consult a Yamaha dealer
before attempting any changes.
WARNING
6-1

PERIODIC MAINTENANCE AND MINOR REPAIR
6
•Check operation, fluid level and vehicle for fluid leakage.
√√√√√ √7 * Rear brake(See NOTE on page 6-4.)
•Replace brake pads. Whenever worn to the limit
8 * Brake hoses•Check for cracks or damage.√√√√ √•Replace. (See NOTE on page 6-4.) Every 4 years
9 * Wheels•Check runout and for damage.√√√√
•Check tread depth and for damage.
10 * Tires•Replace if necessary.
√√√√ √
•Check air pressure.
•Correct if necessary.
11 * Wheel bearings•Check bearing for looseness or damage.√√√√
12 * Steering bearings•Check bearing play and steering for roughness.√√√√√•Lubricate with lithium-soap-based grease. Every 20,000 km
13 * Chassis fasteners•Make sure that all nuts, bolts and screws are
√√√√ √
properly tightened.
14 Sidestand, Centerstand•Check operation.
√√√√ √
•Lubricate.
15 * Sidestand switch•Check operation.√√√√√ √
16 * Front fork•Check operation and for oil leakage.√√√√
17 * Shock absorber assemblies•Check operation and shock absorbers for oil leakage.√√√√
18 * Carburetor•Adjust engine idling speed.√√√√√ √
ODOMETER READING (x 1,000 km)
NO. ITEMCHECK OR MAINTENANCE JOB
1
ANNUAL
CHECK
10 20 30 40
6-3