maintenance YAMAHA VERSITY 300 2004 Owner's Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04591*
Coolant
The coolant reservoir is located under
the panel B. (See page 6-9 for panel
removal and installation procedures.)
To check the coolant level
1. Place the scooter on a level sur-
face and hold it in an upright posi-
tion.
NOTE :
•The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
•Make sure that the scooter is
positioned straight up when
checking the coolant level. A slight
tilt to the side can result in a false
reading.2. Check the coolant level in the
coolant reservoir.
NOTE :
The coolant should be between the
minimum and maximum level marks.
1. Maximum level mark
2. Minimum level mark
3. If the coolant is at or below the
minimum level mark, remove the
reservoir cap, add coolant to the
maximum level mark, and then
install the reservoir cap.
Coolant reservoir capacity:
0.4 L
4. Install the panel.
1. Coolant reservoir cap
6-17
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EC000080
•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 coolant as
soon as possible, otherwise the
engine may not be sufficiently
cooled and the cooling system
will not be protected 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 possible,
otherwise the effectiveness of the
coolant will be reduced.
NOTE :
The radiator fan is automatically
switched on or off according to the
coolant temperature in the radiator. If
the engine overheats, see page 6-37
for further instructions.
CAUTION:EAU03627*
Air filter and V-belt case air
filter elements
The air filter and V-belt case air filter
elements should be cleaned at the
intervals specified in the periodic main-
tenance and lubrication chart. Clean
both filter elements more frequently if
you are riding in unusually wet or dusty
areas.
EC000092*
•Make sure that each filter
element is properly seated in its
case.
•The engine should never be
operated without the filter
elements installed, otherwise
the piston and/or cylinder may
become excessively worn.Cleaning the air filter element
1. Place the scooter on the
centerstand.
2. Remove the air filter case cover
by removing the screws.
CAUTION:
1. Air filter case cover
2. Screw (x5)
3. Sponge material
4. Mesh sheet
6-18
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PERIODIC MAINTENANCE AND MINOR REPAIR
63. Pull the sponge material out along
with the mesh sheet, clean it with
solvent, and then squeeze the
remaining solvent out.
4. Check the sponge material for
damage and replace it if
necessary.
5. Allow the sponge material to dry.
6. Apply oil of the recommended
type to the entire surface of the
sponge material, and then
squeeze the excess oil out.
NOTE :
The sponge material should be wet but
not dripping.
Recommended oil:
Engine oil
7. Insert the sponge material into the
air filter case.
8. Install the air filter case cover by
installing the screws.
Cleaning the V-belt case air filter
element
1. Remove the V-belt case air filter
cover by removing the screws.
1. V-belt case air filter cover
2. Screw (x3)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6 2. Blow the dirt out of the air filter
element with compressed air as
shown.
3. Check the V-belt case air filter
element for damage and replace
it if necessary.
4. Install the V-belt case air filter
element cover by installing the
screws.
1. V-belt case air filter cover
2. V-belt case air filter element
EAU00631
Adjusting the carburetor
The carburetor is an important part of
the engine and requires very
sophisticated adjustment. Therefore, all
carburetor adjustments should be left
to a Yamaha dealer, who has the
necessary professional knowledge and
experience.
EAU00635
Adjusting the throttle cable
free play
The throttle cable free play should
measure 1.5 – 3 mm at the throttle grip.
Periodically check the throttle cable free
play and, if necessary, have a Yamaha
dealer adjust it.
a. Throttle cable free play
6-20
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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
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4
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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 Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail
or glass fragments in it, or if the sidewall
is cracked, have a Yamaha dealer re-
place the tire immediately.
EW000077
Because loading has an enormous
impact on the handling, braking, per-
formance and safety characteristics of
your scooter, you should keep the
following precautions in mind.
•NEVER OVERLOAD THE SCOO-
TER! Operation of an overloaded
scooter may result in tire damage,
loss of control, or severe injury.
Make sure that the total weight of
rider, cargo, and accessories
does not exceed the specified
maximum load for the vehicle.
•Do not carry along loosely
packed items, which can shift
during a ride.
•Securely pack the heaviest items
close to the center of the scooter
and distribute the weight evenly
on both sides.
•Adjust the suspension and tire air
pressure with regard to the load.
•Check the tire condition and air
pressure before each ride.
WARNING
1. Tire tread depth
2. Sidewall
Tire information
This scooter is equipped with tubeless
tires.
Front
Manufacturer Size Type
MICHELIN 120/80-14 58P PILOT CITY TL
Rear
Manufacturer Size Type
MICHELIN 150/70-14 66P PILOT CITY TL
Minimum tire tread depth
(front and rear)1.6 mm
NOTE :
The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
EAU00683
EW000079
•Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
scooter with excessively worn
tires decreases riding stability
and can lead to loss of control.
•The replacement of all wheel
and brake related parts,
including the tires, should be
left to a Yamaha dealer, who has
the necessary professional
knowledge and experience.
WARNING
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03773
Cast wheels
To maximize the performance,
durability, and safe operation of your
scooter, note the following points
regarding the specified wheels.
•The wheel rims should be
checked for cracks, bends or
warpage before each ride. If any
damage is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair
to the wheel. A deformed or
cracked wheel must be replaced.
•The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse
handling characteristics, and a
shortened tire life.
•Ride at moderate speeds after
changing a tire since the tire sur-
face must first be "broken in" for it
to develop its optimal
characteristics.
EAUM0056
Adjusting the front and rear
brake lever free play
The front and rear brake lever free play
should measure 2 — 5 mm as shown.
Periodically check the front and rear
brake lever free play and, if necessary,
have a Yamaha dealer adjust it.
EW000100
An incorrect brake lever free play
indicates a hazardous condition in
the brake system. Do not operate the
scooter until the brake system has
been checked or repaired by a
Yamaha dealer.
WARNING
a. Front brake free playa. Rear brake free play
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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EAU00717
Checking the front and rear
brake pads
The front and rear brake pads must be
checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart. To check the
brake pad wear, measure the lining
thickness. If the lining thickness is less
than 3.8 mm, have a Yamaha dealer
replace the brake pads as a set.
a. Wear limit a. Wear limit 1. Minimum level mark
EAU04856
Checking the brake fluid
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 brake 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.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6Observe these precautions:
•When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.
•Use only the recommended
quality brake fluid, otherwise the
rubber seals may deteriorate,
causing leakage and poor braking
performance.
Recommended brake fluid:
DOT 4
1. Minimum level mark
•Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
•Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will
significantly lower the boiling point
of the fluid and may result in vapor
lock.
•Brake fluid may deteriorate
painted 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.
EAUM0008*
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and
lubrication chart. In addition, have the
brake hoses replaced every four years
or whenever they are damaged or
leaking.
6-25
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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)
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