YAMAHA VERSITY 300 2004 Manual PDF

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.
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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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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03371
Checking and lubricating the
centerstand and sidestand
The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-to-
metal contact surfaces should be
lubricated if necessary.
EW000114
If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or
repair it.
1. Sidestand 1. Centerstand
WARNING
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
EAU02939
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
Securely support the scooter so that
there is no danger of it falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
WARNING
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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.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01144
Checking the wheel bearings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and
lubrication chart. If there is play in the
wheel hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
EAU04464
Battery
The battery is located behind panel B.
(See page 6-9 for panel removal and
installation procedures.)
This scooter is equipped with a sealed-
type (MF) battery, which does not
require any maintenance. There is no
need to check the electrolyte or to add
distilled water.
1. Battery
To charge the battery
Have a Yamaha dealer charge the
battery as soon as possible if it seems
to have discharged. Keep in mind that
the battery tends to discharge more
quickly if the scooter is equipped with
optional electrical accessories.
EW000116
•Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes
severe burns. Avoid any contact
with skin, eyes or clothing and
always shield your eyes when
working near batteries. In case
of contact, administer the
following FIRST AID.
•EXTERNAL: Flush with
plenty of water.
•INTERNAL: Drink large
quantities of water or milk
and immediately call a
physician.
WARNING
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6
•EYES: Flush with water for
15 minutes and seek prompt
medical attention.
•Batteries produce explosive
hydrogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and
provide sufficient ventilation
when charging it in an enclosed
space.
•KEEP THIS AND ALL BATTE-
RIES OUT OF THE REACH OF
CHILDREN.To store the battery
1. If the scooter will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
2. If the battery will be stored for
more than two months, check it
at least once a month and fully
charge it if necessary.
3. Fully charge the battery before
installation.EC000102
•Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.
•To charge a sealed-type (MF)
battery, a special (constant-vol-
tage) battery charger is
required. Using a conventional
battery charger will damage the
battery. If you do not have
access to a sealed-type (MF)
battery charger, have a Yamaha
dealer charge your battery.
CAUTION:
1. Main fuse
2. Spare fuse
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Replacing the fuses
The main fuse box is located behind
panel C. (See page 6-10 for panel
removal and installation procedures.)

PERIODIC MAINTENANCE AND MINOR REPAIR
6
1. Backup fuse
2. Headlight fuse
3. Radiator fan fuse
4. Signaling system fuse
5. Ignition fuse
6. Auxiliary DC jack fuse
7. Spare fuse (x2)
8. Fuse tongs
CAUTION:
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The fuse block, which contains the fu-
ses for the individual circuits, is located
in the storage compartment A. (See
page 3-12 for storage compartment
opening and closing procedures.)If a fuse is blown, replace it as follows.
1. Turn the key to "
" and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
Specified fuses:
Main fuse Box
Main fuse: 30 A
Fuse block
Backup fuse 3 A
Headlight fuse: 15 A
Radiator fan fuse: 15 A
Signaling system fuse: 15 A
Ignition fuse: 7.5 A
Auxiliary DC jack fuse: 3 A3. Turn the key to "
" and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EC000103
Do not use a fuse of a higher
amperage rating than recommended
to avoid causing extensive damage
to the electrical system and possibly
a fire.

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04285
Replacing the headlight bulb
This scooter is equipped with a quartz
bulb headlight. If the headlight bulb
burns out, replace it as follows.
1. Remove cowling A together with
the headlight unit. (See page 6-7
for cowling removal and installa-
tion procedures.)
WARNING
1. Bulb cover
2. Headlight coupler
3. Remove the headlight bulb holder
by pushing it inward and turning
it counterclockwise, and then
remove the defective bulb.
EW000119
Headlight bulbs get very hot.
Therefore, keep flammable products
away from a lit headlight bulb, and
do not touch the bulb until it has
cooled down. 2. Disconnect the headlight coupler,
and then remove the bulb cover.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
CAUTION:4. Place a new headlight bulb into
position, and then secure it with
the bulb holder.EC000105
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of the
glass, the luminosity of the bulb, and
the bulb life will be adversely
affected. Thoroughly clean off any
dirt and fingerprints on the headlight
bulb using a cloth moistened with
alcohol or thinner.
5. Install the headlight bulb cover,
and then connect the coupler.
6. Install the cowling together with
the headlight unit.7. Have a Yamaha dealer adjust the
headlight beam if necessary.
a. Do not touch the glass part of the bulb
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