engine YAMAHA VERSITY 300 2005 Owner's Guide

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
EAU21401
Valve clearance 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.
EAUM2040
Tires To maximize the performance, durabil-
ity, and safe operation of your vehicle,
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.
WARNING
EWA10500


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 ad-
justed in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approvedfor this model.
ZAUM0053
Tire air pressure (measured on cold
tires):
0–90 kg (0–198 lb):
Front:
180 kPa (26 psi) (1.80 kgf/cm²)
Rear:
190 kPa (28 psi) (1.90 kgf/cm²)
90–160 kg (198–353 lb):
Front:
180 kPa (26 psi) (1.80 kgf/cm²)
Rear:
200 kPa (29 psi) (2.00 kgf/cm²)
160–202 kg (353–445 lb):
Front:
190 kPa (28 psi) (1.90 kgf/cm²)
Rear:
220 kPa (32 psi) (2.20 kgf/cm²)
Maximum load*:
202 kg (445 lb)
* Total weight of rider, passenger, car-
go and accessories

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
EAU23100
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 ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING
EWA10720
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafeconditions.
EAU23110
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.
EAU23170
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:
Engine oil
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)ZAUM0061

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6 2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
CAUTION:
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-pair it.
EAU23280
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
ZAUM0457

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU25921
Troubleshooting charts Starting problems or poor engine performance
WARNING
EWA10840
Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6 Engine overheating
WARNING
EWA10400


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 hissingsound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
NOTE:If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolantas 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.

SCOOTER CARE AND STORAGE
7-1
7
EAU26090
Care While the open design of a scooter re-
veals the attractiveness of the technol-
ogy, it also makes it more vulnerable.
Rust and corrosion can develop even if
high-quality components are used. A
rusty exhaust pipe may go unnoticed
on a car, however, it detracts from the
overall appearance of a scooter. Fre-
quent and proper care does not only
comply with the terms of the warranty,
but it will also keep your scooter looking
good, extend its life and optimize its
performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-ucts onto seals, gaskets and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
CAUTION:
ECA10780


Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.


Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.


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 orthinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.


Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm 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 com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den 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 afterwashing.

SCOOTER CARE AND STORAGE
7-3
7


Avoid using abrasive polishing
compounds as they will wearaway the paint.
NOTE:Consult a Yamaha dealer for advice onwhat products to use.
EAU26300
Storage Short-term
Always store your scooter in a cool, dry
place and, if necessary, protect it
against dust with a porous cover.CAUTION:
ECA10820


Storing the scooter in a poorly
ventilated room or covering it
with a tarp, while it is still wet,
will allow water and humidity to
seep in and cause rust.


To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-cals are stored.
Long-term
Before storing your scooter for several
months:
1. Follow all the instructions in the
“Care” section of this chapter.2. Drain the carburetor float chamber
by loosening the drain bolt; this will
prevent fuel deposits from building
up. Pour the drained fuel into the
fuel tank.
3. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
4. Perform the following steps to pro-
tect the cylinder, piston rings, etc.
from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine oil
into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap.

SCOOTER CARE AND STORAGE
7-4
7
WARNING
EWA10950
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turningthe engine over.
5. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the side-
stand/centerstand.
6. Check and, if necessary, correct
the tire air pressure, and then lift
the scooter so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
7. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.
8. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place [less
than 0 °C (30 °F) or more than 30°C (90 °F)]. For more information
on storing the battery, see page
6-25.
NOTE:Make any necessary repairs beforestoring the scooter.

SPECIFICATIONS
8-1
8
Dimensions:Overall length:
2170 mm (85.4 in)
Overall width:
765 mm (30.1 in)
Overall height:
1465 mm (57.7 in)
Seat height:
805 mm (31.7 in)
Wheelbase:
1480 mm (58.3 in)
Ground clearance:
155 mm (6.10 in)
Minimum turning radius:
1706 mm (67.2 in)Weight:With oil and fuel:
174.0 kg (384 lb)Engine:Engine type:
Liquid cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
264.0 cm³ (16.11 cu.in)
Bore × stroke:
71.0 × 66.8 mm (2.80 × 2.63 in)
Compression ratio:
10.00 :1
Starting system:
Electric starter
Lubrication system:
Wet sump
Engine oil:Type:
SAE10W30 or SAE10W40 or SAE15W40
or SAE20W40 or SAE20W50
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine oil quantity:
Periodic oil change:
1.20 L (1.27 US qt) (1.06 Imp.qt)Final transmission oil:Type:
SAE10W30 type SE motor oil
Quantity:
0.25 L (0.26 US qt) (0.22 Imp.qt)Cooling system:Coolant reservoir capacity (up to the
maximum level mark):
0.40 L (0.42 US qt) (0.35 Imp.qt)
Radiator capacity (including all routes):
1.60 L (1.69 US qt) (1.41 Imp.qt)
Air filter:Air filter element:
Wet elementFuel:Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
10.9 L (2.88 US gal) (2.40 Imp.gal)
Fuel reserve amount:
1.9 L (0.50 US gal) (0.42 Imp.gal)Carburetor:Manufacturer:
TEIKEI
Type x quantity:
Y28V-1J x 1Spark plug(s):Manufacturer/model:
NGK/DR8EA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)Clutch:Clutch type:
Dry, centrifugal automaticTransmission:Primary reduction system:
Helical gear
Primary reduction ratio:
40/15 (2.666)
Secondary reduction system:
Helical gear
Secondary reduction ratio:
37/12 (3.083)
Transmission type:
V-belt automatic
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40

INDEX
AAcceleration and deceleration ................ 5-2
Air filter and V-belt case air filter
elements, cleaning ............................. 6-14
Anti-theft alarm (optional) ....................... 3-7
Anti-theft device housing ...................... 3-13
Auxiliary DC jack .................................. 3-17BBattery .................................................. 6-25
Battery voltage/coolant temperature
gauge ................................................... 3-3
Brake fluid, changing ............................ 6-21
Brake fluid level, checking .................... 6-20
Brake lever, front .................................... 3-8
Brake lever, rear ..................................... 3-9
Brake levers, lubricating ....................... 6-22
Braking ................................................... 5-2CCables, checking and lubricating .......... 6-22
Carburetor,adjusting ............................. 6-16
Care ........................................................ 7-1
Catalytic converter ................................ 3-11
Centerstand and sidestand, checking
and lubricating .................................... 6-23
Coolant ................................................. 6-13
Cowlings and panels, removing and
installing ............................................... 6-5DDimmer switch ........................................ 3-7
Display, multi-function ............................ 3-4EEngine break-in ...................................... 5-3
Engine oil .............................................. 6-10
Engine stop switch.................................. 3-8
FFinal transmission oil.............................6-12
Front and rear brake lever free play,
checking .............................................. 6-19
Front and rear brake pads, checking .... 6-20
Front fork, checking...............................6-23
Fuel ....................................................... 3-10
Fuel consumption, tips for reducing ........ 5-3
Fuel gauge .............................................. 3-3
Fuel tank cap........................................... 3-9
Fuses, replacing .................................... 6-26HHandlebar switches ................................. 3-7
Hazard switch.......................................... 3-8
Headlight bulb, replacing....................... 6-27
High beam indicator light......................... 3-2
Horn switch ............................................. 3-8IIdentification numbers ............................. 9-1
Ignition circuit cut-off system ................. 3-15
Indicator lights .........................................3-2KKey identification number ........................ 9-1LLicense plate light bulb, replacing ......... 6-30
Low beam indicator light ......................... 3-2
Luggage hook ....................................... 3-14MMain switch/steering lock ........................ 3-1
Model label .............................................. 9-2PParking ....................................................5-4
Part locations .......................................... 2-1
Pass switch ............................................. 3-7Periodic maintenance and lubrication
chart...................................................... 6-2
Pre-operation check list .......................... 4-2
SSafe-riding points .................................... 1-4
Safety information ................................... 1-1
Seat ...................................................... 3-11
Shock absorber assemblies,
adjusting ............................................. 3-14
Sidestand .............................................. 3-15
Spark plug, checking .............................. 6-9
Specifications.......................................... 8-1
Speedometer .......................................... 3-2
Starting off .............................................. 5-2
Starting the engine.................................. 5-1
Start switch ............................................. 3-8
Steering, checking ................................ 6-24
Storage ................................................... 7-3
Storage compartment .................. 3-12, 3-13TTail/brake light bulb or rear turn signal
light bulb, replacing............................. 6-29
Throttle cable free play, checking ......... 6-16
Throttle grip and cable, checking and
lubricating ........................................... 6-22
Tires ...................................................... 6-17
Tool kit .................................................... 6-1
Troubleshooting .................................... 6-30
Troubleshooting charts ......................... 6-31
Turn signal indicator lights ...................... 3-2
Turn signal light bulb (front),
replacing ............................................. 6-28
Turn signal switch ................................... 3-7