YAMAHA VERSITY 300 2004 Workshop Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6
•Change. (See page 3-7 for more information about the√When the oil change indicator comes on19 Engine oil oil change indicator)( Every 3000 km)
•Check oil level and vehicule for oil leakage. Every 3,000 km√
20 * Engine oil strainer•Clean.√
21 * Cooling system•Check coolant level and vehicule for coolant leakage.√√√√ √•Change. Every 3 years
22Final transmission oil•Check vehicle for oil leakage.√√ √•Change.√√√
23 * V-belt•Replace. Every 20,000 km
24 *Front and rear brake
•Check operation.√√√√√ √
switches
25 Moving parts and cables•Lubricate.√√√√ √
Throttle grip housing•Check operation and free play.
26 *
and cable•Adjust the throttle cable free play if necessary.√√√√ √
•Lubricate the throttle grip housing and cable.
27 *Lights, signals•Check operation.
√√√√√ √
and switches•Adjust headlight beam.
ODOMETER READING (x 1,000 km)
NO. ITEMCHECK OR MAINTENANCE JOB
1
ANNUAL
CHECK
10 20 30 40
EAU03884*
NOTE :
•The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
•Hydraulic brake service
•Regularly check and, if necessary, correct the brake fluid level.
•Every two years change the brake fluid.
•Replace the brake hoses every four years and if cracked or damaged.
6-4

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01139
Removing and installing
cowlings and panels
The cowlings and panels shown above
need to be removed to perform some
of the maintenance jobs described in
this chapter. Refer to this section each
time a cowling or panel needs to be
removed and installed.
1
ZAUM04211ZAUM0422
1. Cowling A 1. Cowling B
6-5
1
2
ZAUM0420
1. Windshield
2. Panel A

PERIODIC MAINTENANCE AND MINOR REPAIR
6
1
ZAUM0425
1
ZAUM0424
1. Panel B 1. Panel C
6-6
1
ZAUM0426
1. Panel D

PERIODIC MAINTENANCE AND MINOR REPAIR
6
1. Cowling A
2. Screw (x 8)
3. Floorboard mat (x2)1. Turn signal lead coupler
2. Headlight coupler
6-7
3 2 1
ZAUM042712ZAUM0428
EAUM0105*
Cowling A
To remove the cowling
1. Pull up the floorboard mat on each
side of the scooter.
2. Remove panel A. (See page 6-9
for removal and installation
procedures.)
3. Remove the cowling screws.4. Disconnect the headlight coupler
and the turn signal lead coupler.
5. Pull the cowling off.
To install the cowling
1. Connect the headlight coupler,
and the turn signal lead coupler.
2. Place the cowling in the original
position, and then install the
screws.
3. Install panel A.
4. Place the floorboard mats in their
original position.
1
ZAUM0584
1. Panel E

PERIODIC MAINTENANCE AND MINOR REPAIR
6
1. Floorboard mat (x2)
1. Screw (x 4)
2. Cowling B 1. Screw (x5)
2. Cowling B
6-8
1
2
ZAUM04292
1
ZAUM0430
1
ZAUM0435
EAUM0106
Cowling B
To remove the cowling
1. Pull up the floorboard mat on each
side of the scooter.2. Remove the screws on each side
of scooter, and then take the
cowling off.To install the cowling
1. Place the cowling in the original
position, and then install the
screws.
2. Place the floorboard mats in their
original position.

PERIODIC MAINTENANCE AND MINOR REPAIR
6
1. Windshield
2. Screw (x4)1. Screw (x2)
2. Panel A
6-9
2 1
ZAUM0432
1
2
ZAUM0433
EAUM0108
Panel A
To remove the panel
1. Remove the screws, and then take
the windshield off.2. Remove the screws, and then pull
the panel out as shown.
To install the panel
1. Place the panel in the original po-
sition, and then install the screws.
2. Place the windshield in the origi-
nal position, and then install the
screws.
EAU01535
Panel B
To remove the panel
Remove the screw, and then pull the
panel off as shown.
To install the panel
Place the panel in the original position,
and then install the screw.
1. Screw (x1)
2. Panel B
1
2
ZAUM0434

PERIODIC MAINTENANCE AND MINOR REPAIR
6
1. Floorboard mat
6-10 1. Panel C
1
ZAUM0435
1
ZAUM0436
EAUM0109
Panel C
To remove the panel
1. Pull up the right floorboard mat.2. Remove the panel as shown.To install the panel
1. Place the panel in the original
position.
2. Place the floorboard mat in the
original position.
EAU00494
Panel D
To remove the panel
Pull the panel off as shown.
To install the panel
Place the panel in the original position.
1. Panel D
1
ZAUM0437

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03620
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 main-
tenance and lubrication chart. In addi-
tion, the condition of the spark plug can
reveal the condition of the engine.
To remove the spark plug
1. Remove cowling B. (See page 6-
8 for cowling removal and instal-
lation procedures.)
2. Remove the spark plug cap.
1. Spark plug
6-11
1
ZAUM0438
12
ZAUM0585
EAU01535
Panel E
To remove the panel
Remove the screw, and then pull the
panel off as shown.
To install the panel
Place the panel in the original position,
and then install the screw.
1. Panel E
2. Screw

PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. 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 insulator
around the center electrode of the
spark plug is a medium-to-light
tan (the ideal color when the scoo-
ter is ridden normally).
NOTE :
If the spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the scooter.
2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
Specified spark plug:
DR8EA (NGK)To install the spark plug
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
Spark plug gap:
0.6 – 0.7 mm
2. Clean the surface of the spark
plug gasket and its mating sur-
face, 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.
1. Spark plug wrencha. Spark plug gap
6-12
1
ZAUM0036
a
ZAUM0037

PERIODIC MAINTENANCE AND MINOR REPAIR
6Tightening torque:
Spark plug:
17.5 Nm (1.75 m
•kg)
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. However, the spark
plug should be tightened to the
specified torque as soon as possible.
4. Install the spark plug cap.
5. Install the cowling.
6-13
EAUM0103*
Engine oil
The engine oil level should be checked
before each ride. In addition, the oil
must be changed at the intervals
specified in the periodic maintenance
and lubrication chart and when the oil
change indicator comes on.To check the engine oil level
1. Place the scooter on the
centerstand.
NOTE :
Make sure that the scooter is positioned
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.