brake fluid YAMAHA VERSITY 300 2004 Owners Manual

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

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
EAU03685
Periodic maintenance and lubrication chart
NOTE :
•The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
•From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
•Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
1 * Fuel line•Check fuel hoses and vacuum hose for cracks or damage.√√√√ √
•Check condition.
√√
2 Spark plug•Clean and regap.
•Replace.√√
3 * Valves•Check valve clearance.
√√
•Adjust.
4 Air filter element•Clean.√√•Replace.√√
5 V-belt case air filter element•Clean.√√√√
•Check operation, fluid level and vehicle for fluid leakage.
√√√√√ √
6 * Front brake(See NOTE on page 6-4.)
•Replace brake pads. Whenever worn to the limit
ODOMETER READING (x 1,000 km)
NO. ITEMCHECK OR MAINTENANCE JOB
1
ANNUAL
CHECK
10 20 30 40
6-2

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

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
a
ZAUM0450
a
ZAUM0451
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.
6-24
FRONTREAR
MIN1
ZAUM0453
FRONT

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
MIN1
ZAUM0452
REAR

SCOOTER CARE AND STORAGE
7
•Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust
removers or inhibitors, brake
fluid, antifreeze or electrolyte.
•Do not use high-pressure
washers or steam-jet cleaners
since they cause water
seepage and deterioration in
the following areas: seals (of
wheel and swingarm bearings,
fork and brakes), electric
components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.
•For scooters equipped with a
windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the
windshield. Test the product on
a small hidden part of the
windshield to make sure that it
does not leave any marks. If the
windshield is scratched, use a
quality plastic polishing
compound after washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea
or on salt-sprayed roads
Since sea salt or salt sprayed on the
roads during winter are extremely cor-
rosive in combination with water, carry
out the following steps after each ride
in the rain, near the sea or on salt-
sprayed roads.
NOTE :
Salt sprayed on roads in the winter may
remain well into spring.
1. Clean the scooter with cold water
and a mild detergent after the
engine has cooled down.
ECA00012
Do not use warm water since it
increases the corrosive action of the
salt.
2. Apply a corrosion protection spray
on all metal, including chrome-
and nickel-plated, surfaces to
prevent corrosion.
CAUTION:
7-2

SPECIFICATIONS
8
Wheels:
Front
Type Cast wheel
Size 14 x MT 2.75
Rear
Type Cast wheel
Size 14 x MT 4.00
Brakes:
Front
Type Single disc brake
Operation Right hand
Type brake fluid DOT 4
Rear
Type Single disc brake
Operation Left hand
Type brake fluid DOT 4
Suspension:
Front suspension Telescopic fork
Rear suspension Unit swing
Shock absorber:
Front fork type Coil spring/oil damper
Rear shock absorber Coil spring/oil damper
assembly type
Wheel travel:
Front wheel travel 108 mm
Rear wheel travel 120 mmElectrical:
Ignition system type Transistorized coil ignition
Charging system AC magneto
Battery
Model F9-12B
Voltage/capacity 12 V / 9 Ah
Headlight type:Halogen bulb
Bulbs (voltage/wattage x quantity):
Headlight 12V, 35W/35Wx2
Auxiliary light 12V, 5Wx2
Tail/brake light 12V, 5W/21Wx2
Turn signal light
Front 12V, 21Wx2
Rear 12V, 10Wx2
High beam indicator light LED
Turn signal indicator light LED
Headlight indicator light LED
Fuses:
Main fuse: 30 A
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 A
Reserve fuse (x quantity) 30Ax1, 15Ax1, 7.5Ax1
8-3

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