check engine YAMAHA VERSITY 300 2004 Owner's Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00637
Adjusting the valve clea-
rance
The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU04551*
Tires
To maximize the performance,
durability, and safe operation of your
scooter, 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.
EW000082
•The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
•The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger,
cargo, and accessories
approved for this model.
WARNING
Maximum load* 202 k g
* Total weight of rider, passenger, cargo and
accessories
6-21
0 12
3
4
ZAUM0053
Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg*180 kPa
1.8 kgf/cm
2
1.8 bar190 kPa
1.9 kgf/cm
2
1.9 bar
90 kg ~ 160 kg load*
180 kPa
1.8 kgf/cm2
1.8 bar200 kPa
2.0 kgf/cm
2
2.0 bar
160 kg ~
maximum load*
190 kPa
1.9 kgf/cm2
1.9 bar220 kPa
2.2 kgf/cm
2
2.2 bar

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU02962
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 cables
and cable ends should be lubricated if
necessary. If a cable is damaged or does
not move smoothly, have a Yamaha dea-
ler check or replace it.
Recommended lubricant:
Engine oil
EW000112
Damage to the outer sheath may
interfere with proper cable operation
and will cause the inner cable to rust.
Replace a damaged cable as soon
as possible to prevent unsafe con-
ditions.
WARNING
EAU04034
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in the
periodic maintenance chart.
EAU03118
Lubricating the front and
rear brake levers
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.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
6-26
ZAUM0061

PERIODIC MAINTENANCE AND MINOR REPAIR
6 To check the operation
1. Place the scooter on a level sur-
face and hold it in an upright po-
sition.
2. While applying the front brake,
push down hard on the
handlebars several times to check
if the front fork compresses and
rebounds smoothly.
EC000098
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
CAUTION:
EAU00794
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Place a stand under the engine
to raise the front wheel off the
ground.
EW000115
Securely support the scooter so that
there is no danger of it falling over.
WARNING
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the
steering.
6-28
ZAUM0456ZAUM0457

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01581
Troubleshooting charts
Starting problems or poor engine performanceEW000125
Keep away open flames and do not smoke while checking or working on the fuel system.
WARNING
Check the fuel level in
the fuel tank.
1. FuelThere is enough fuel.
There is no fuel.Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.
2. CompressionThere is compression.
There is no compression.Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.
3. IgnitionWipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.
4. BatteryThe engine turns over
quickly.
The engine turns over
slowly.The battery is good.
Check the battery lead connections,
and charge the battery if necessary.
Dry
WetOpen the throttle halfway and operate
the electric starter.
6-36

PERIODIC MAINTENANCE AND MINOR REPAIR
6Engine overheating
EW000070
•Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
•After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing
sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
WARNING
NOTE :
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.
Wait until the
engine has cooled.Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.
The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.
Add coolant. (See NOTE.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
There is
leakage.
There is
no leakage.
6-37

SCOOTER CARE AND STORAGE
7 Long-term
Before storing your scooter for several
months:
1. Follow all the instructions in the
"Care" section of this chapter.
2. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
fuel tank.
3. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
4. Perform the following steps to
protect the cylinder, piston rings,
etc. from corrosion.
a. Remove the spark plug cap and
spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit
sparking during the next step.)d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap from
the spark plug, and then install
the spark plug and the spark
plug cap.
EWA00003
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
5. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
6. Check and, if necessary, correct
the tire air pressure, and then lift
the scooter so that both of its
wheels are off the ground.
Alternatively, turn the wheels a
little every month in order to
prevent the tires from becoming
degraded in one spot.
WARNING
7. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
8. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an
excessively cold or warm place
(less than 0 °C or more than 30
°C). For more information on
storing the battery, see page
6-30.
NOTE :
Make any necessary repairs before
storing the scooter.
7-4

INDEX
A
Acceleration and deceleration ............. 5-3
Air filter and V-belt case air filter
elements, cleaning ....................... 6-18
Anti-theft alarm (optional) ................... 3-7
Auxiliary DC jack ............................... 3-18
Anti-theft device housing ................... 3-14
B
Battery .............................................. 6-29
Battery voltage / coolant
temperature gauge ......................... 3-3
Brake fuid level, checking ................. 6-24
Brake fluid, changing ........................ 6-25
Bake lever, front .................................. 3-9
Brake lever, rear .................................. 3-9
Brake levers, lubricating .................... 6-26
Brake pads, checking ........................ 6-24Braking ................................................ 5-3
C
Cables, checking and lubricating ...... 6-26
Carburator, adjusting ......................... 6-20
Care .................................................... 7-1
Catalytic converter ............................ 3-11
Centerstand and sidestand, checking
and lubricating .............................. 6-27
Conversion table ................................. 8-4
Coolant .............................................. 6-17
Cowlings and panels, removing
and installing .................................. 6-5
E
Engine break-in ................................... 5-4
Engine oil .......................................... 6-13
F
Final transmission oil ........................ 6-16
Front and rear brake lever free play,
adjusting ....................................... 6-23
Front fork, checking ........................... 6-27
Fuel ................................................... 3-10
Fuel consumption, tips for reducing .... 5-4
Fuel gauge .......................................... 3-3
Fuel tank cap .................................... 3-10Fuses, replacing ................................ 6-30
H
Handlebar switches ............................. 3-8
Dimmer switch ............................... 3-8
Engine stop switch ......................... 3-8
Horn switch .................................... 3-8
Hazard switch ................................ 3-9
Pass switch .................................... 3-8
Start switch .................................... 3-8
Turn signal switch ........................... 3-8
Headlight bulb, replacing ................... 6-32
I
Identification number ........................... 9-1
Ignition circuit cut-off system ............. 3-16
Indicator lights ..................................... 3-2
High beam indicator light ............... 3-2
Low beam indicator light ................ 3-2
Turn signal indicator lights .............. 3-2
K
Key identification number .................... 9-1
L
License plate liht bulb, replacing ....... 6-35

INDEX
Storage compartments ...................... 3-12
T
Tail/brake light bulb or rear turn
signal light bulb, replacing ............ 6-34
Throtlle cable free play, adjusting ...... 6-20
Throttle grip and cable,
checking and lubricating .............. 6-26
Tires .................................................. 6-21
Tool kit ................................................. 6-1
Troubleshooting ................................. 6-35
Troubleshooting charts ...................... 6-36
Turn signal light bulb (front),
replacing ...................................... 6-34
V
Valve clearance, adjusting ................ 6-21
Vehicule identification number ............ 9-1
W
Wheel bearing, checking ................... 6-29
Wheels .............................................. 6-23 Luggage hook ................................... 3-15
M
Main switch/steering lock .................... 3-1
Model label .......................................... 9-2
Multi-function display .......................... 3-4
P
Parking ................................................ 5-5
Part locations ...................................... 2-1
Periodic maintenance and lubrication
chart ............................................... 6-2
Pre-operation check list ...................... 4-1
S
Safe-riding points ................................ 1-2
Seat ................................................... 3-12
Shock absorber assemblies,
adjusting ....................................... 3-14
Sidestand .......................................... 3-16
Spark plug, checking ......................... 6-11
Specifications ...................................... 8-1
Speedometer ...................................... 3-2
Starting off .......................................... 5-2
Starting the engine .............................. 5-1
Steering, checking ............................ 6-28
Storage ............................................... 7-3