coolant YAMAHA VERSITY 300 2004 Owners Manual

2
DESCRIPTION
Left view
1
2 3 4 5 6
1. Rear storage compartment (Page 3-13)
2. Shock absorber spring preload
adjusting ring (Page 3-14)
3. Air filter element (Page 6-18)4. V-belt case air filter element (page 6-18)
5. Sidestand (page 3-16, 6-27)
6. Coolant level check window (page 6-17)
2-1

2
DESCRIPTION
Right view
7. Grab bar (Page 5-2)
8. Fuel tank cap (Page 3-10)
9. Battery (Page 6-29)
10. Coolant reservoir cap (Page 6-17)
11. Front brake pads (page 6-24)12. Main fuse box (page 6-30)
13. Engine oil filler cap (page 6-13)
14. Centerstand (page 6-27)
15. Rear brake pads (page 6-24)
7
15 14 13 12 118910
2-2

EAU00027
INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock .................................................................... 3-1
Indicator lights ..................................................................................... 3-2
Speedometer ...................................................................................... 3-2
Fuel gauge .......................................................................................... 3-3
Battery voltage/coolant temperature gauge ........................................ 3-3
Multi-function display .......................................................................... 3-4
Anti-theft alarm (optional) .................................................................... 3-7
Handlebar switches ............................................................................. 3-8
Front brake lever ................................................................................. 3-9
Rear brake lever .................................................................................. 3-9
Fuel tank cap .................................................................................... 3-10
Fuel ................................................................................................... 3-10
Catalytic converter ............................................................................ 3-11
Seat ................................................................................................... 3-12
Storage compartments ...................................................................... 3-12
Anti-theft device housing ................................................................... 3-14
Adjusting the shock absorber assemblies ......................................... 3-14
Luggage hook ................................................................................... 3-15
Sidestand .......................................................................................... 3-16
Ignition circuit cut-off system ............................................................. 3-16
Auxiliary DC jack ............................................................................... 3-18
3

3
INSTRUMENT AND CONTROL FUNCTIONS
EAUM0098
Fuel gauge
The fuel gauge indicates the amount of
fuel in the fuel tank. The needle moves
towards "E" (Empty) as the fuel level
decreases. When the remaining fuel in
the tank reaches approximately 1.9 L, the
fuel level warning light will come on and
the multi-function display will
automatically change to the "Trip/Fuel"
mode. (See page 3-4 — 3-5 for details.).
If this occurs, refuel as soon as possible.
NOTE :
Do not allow the fuel tank to empty itself
completely.
EAUM0099*
Battery voltage/coolant
temperature gauge
When the key is turned to "", this
gauge indicates the battery voltage
level before the engine was stopped.
NOTE :
If the needle drops to the "9V" mark,
have a Yamaha dealer check the
battery.When the key is turned to "
", this
gauge indicates the coolant
temperature. If the needle reaches the
red zone, stop the scooter and allow
the engine to cool. (See page 6-17 for
details.)
EC000002
Do not operate the engine if it is
overheated.
CAUTION:
1. Fuel gauge
2. Fuel warning light1. High level
2. Low level1. Red zone
O1O1O
2O2O
4O4O
6O6O
F
1/21/2
E
1
2
ZAUM0403
3-3
10O10O
12O12O
14O14O
16O16O
H
C15V15V
9V9V
1
2
ZAUM0579
10O
12O
14O
16O
H
C15V 15V
9V 9V1
ZAUM0580

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
•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
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
1
2
ZAUM0444
1
ZAUM0445

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
1
2 2
34ZAUM0446

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