check oil YAMAHA WHY 50 2003 Owners Manual

3
INSTRUMENT AND CONTROL FUNCTIONS
PUSH
OPEN
ZAUM0253
EAU00029
Main switch/steering lock
The main switch/steering lock controls
the ignition and lighting systems, and
is used to lock the steering. The various
positions are described below.
EAU00038
OFF “”
All electrical systems are off. The key
can be removed.
EAU04470
CHECK “”
The 2-stroke engine oil level warning
light should come on. See page 3-2 for
an explanation of the engine oil level
warning light.
EAU00040
LOCK “ ”
The steering is locked, and all electrical
systems are off. The key can be
removed.
To lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “
”
position, and then turn it to “
”
while still pushing it.
3. Remove the key.
To unlock the steering
Push the key in, and then turn it to “
”
while still pushing it.
EW000016
Never turn the key to “ ” or “ ”
while the scooter is moving, otherwise
the electrical systems will be switched
off, which may result in loss of control
or an accident. Make sure that the scoo-
ter is stopped before turning the key
to “ ” or “ ”.
EAU04384
ON “ ”
All electrical circuits are supplied with
power, the taillight and meter lighting
come on, and the engine can be
started. The key cannot be removed.
NOTE :
The headlight comes on as soon as the
engine is started.
3-1

INSTRUMENT AND CONTROL FUNCTIONS
312ZAUM0184
1. Turn signal indicator light ""
2. High beam indicator light "
`"
EAU00057
Turn signal indicator light ""
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
EAU00063
High beam indicator light ""
This indicator light comes on when the
high beam of the headlight is switched
on.
1
ZAUM0357
1. Oil level indicator light ""
EAU02958
Oil level warning light ""
This warning light comes on when the
key is in the "
" position or when the
oil level in the 2-stroke engine oil tank
is low during operation. If the warning
light comes on during operation, stop
immediately and fill the oil tank with
Yamalube 2 or equivalent 2-stroke
engine oil of either JASO grade "FC"
or ISO grades "EG-C" or "EG-D". The
warning light should go off after the 2-
stroke engine oil tank has been refilled.
NOTE :
If the warning light does not come on
when the key is in the "
" position or
does not go off after the 2-stroke engine
oil tank has been refilled, have a
Yamaha dealer check the electrical cir-
cuit.
EC000000
Do not operate the scooter until you
know that the engine oil level is
sufficient.
3-2
EAU03034
Indicator and warning lights

PRE-OPERATION CHECKS
4
•Check fuel level in fuel tank.
Fuel•Refuel if necessary. 3-5 — 3-6
•Check fuel line for leakage.
•Check oil level in oil tank.
2-stroke engine oil•If necessary, add recommended oil to specified level. 3-5 — 3-7
•Check vehicle for oil leakage.
Final transmission oil•Check vehicle for oil leakage. 6-6
•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
Front brake•Check fluid level in reservoir. 3-5, 6-13 — 6-15
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.
•Check operation.
Rear brake•Check pedal free play. 3-5, 6-13 — 6-15
•Adjust if necessary.
•Make sure that operation is smooth.
Throttle grip•Check cable free play.
6-9, 6-15
•If necessary, have Yamaha dealer adjust cable free play
and lubricate cable and grip housing.
The 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
4-1

OPERATION AND IMPORTANT RIDING POINTS
5
EAU01118
EW000129
•Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or
function that you do not
thoroughly understand.
•Never start the engine or
operate it in a closed area for
any length of time. Exhaust fu-
mes are poisonous, and
inhaling them can cause loss of
consciousness and death
within a short time. Always
make sure that there is
adequate ventilation.
•For safety, always start the
engine with the centerstand
down.
EAU02960
Starting the engineEC000046
See page 5-4 for engine break-in ins-
tructions prior to operating the
vehicle for the first time.
1. Turn the key to "
", and when the
oil level warning light comes on,
turn it to "
".EC000045
If the oil level warning light does not
come on, have a Yamaha dealer
check the electrical circuit.
2. Close the throttle completely.3. While applying the front or rear
brake, start the engine by pushing
the start switch or by pushing the
kickstarter lever down.
NOTE :
If the engine fails to start by pushing
the start switch, release the switch, wait
a few seconds, and then try again. Each
starting attempt should be as short as
possible to preserve the battery. Do not
crank the engine more than 5 seconds
on any one attempt. If the engine does
not start with the starter motor, try using
the kickstarter.
ZAUM0367
PUSH
OPEN
ZAUM0253
5-1

OPERATION AND IMPORTANT RIDING POINTS
5
EAU00436
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1,000 km. For this
reason, you should read the following
material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,000 km. The various parts in the
engine wear and polish themselves to
the correct operating clearances.
During this period, prolonged full-
throttle operation or any condition that
might result in engine overheating must
be avoided.
EAUT0003*
0 — 150 km
Avoid operation above 1/3 throttle. Stop
the engine and let it cool for 5 to 10
minutes after every hour of operation.
Vary the speed of the scooter from time
to time. Do not operate it at one set
throttle position.150 — 500 km
Avoid prolonged operation above 1/2
throttle.
500 — 1,000 km
Avoid cruising speeds in excess of 3/
4 throttle.
ECAT0001
After 1,000 km of operation, be sure
to replace the final transmission oil.
1,000 km and beyond
Avoid prolonged full throttle operation.
Vary speeds occasionally.
EC000049
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
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Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EW000058
•Since the engine and exhaust
system can become very hot,
park in a place where
pedestrians or children are not
likely to touch them.
•Do not park on a slope or on
soft ground, otherwise the
scooter may overturn.
EC000062
Never park in an area where there
are fire hazards such as grass or
other flammable materials.
5-4

EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR
Periodic maintenance and lubrication chart ............ 6-2
Removing and installing the panel .......................... 6-5
Panel A .................................................................... 6-5
Checking the spark plug ......................................... 6-5
Final transmission oil .............................................. 6-6
Cleaning the air filter element ................................. 6-7
Adjusting the carburetor .......................................... 6-9
Adjusting the throttle cable free play ....................... 6-9
Tires ...................................................................... 6-10
Cast wheels .......................................................... 6-11
Adjusting the front brake lever free play ................ 6-12
Adjusting the front brake lever free play ................ 6-12
Checking the front brake pads .............................. 6-13
and rear brake shoes
Checking the brake fluid level ............................... 6-14
6 Changing the brake fluid ....................................... 6-15
Checking and lubricating the throttle grip .............. 6-15
and cable
Lubricating the front and rear brakes levers .......... 6-15
Checking and lubricating the centerstand ............. 6-16
Checking the front fork .......................................... 6-16
Checking the steering ........................................... 6-17
Checking the wheel bearings ................................ 6-17
Battery ................................................................... 6-18
Replacing the fuse ................................................ 6-19
Replacing a headlight bulb .................................... 6-20
Replacing the brake taillight bulb .......................... 6-21
Replacing a turn signal light bulb .......................... 6-21
Troubleshooting ..................................................... 6-22
Troubleshooting chart ............................................ 6-23

PERIODIC MAINTENANCE AND MINOR REPAIR
6
•Check tread depth and for damage.
9 * Tires•Replace if necessary.
√√√√ √
•Check air pressure.
•Correct if necessary.
10 * Wheel bearings•Check bearing for looseness or damage.√√√√
11 * Steering bearings•Check bearing play and steering for roughness.√√√√√•Lubricate with lithium-soap-based grease. Every 24,000 km
12 * Chassis fasteners•Make sure that all nuts, bolts and screws are
√√√√ √
properly tightened.
13 Centerstand•Check operation.
√√√√ √
•Lubricate.
14 * Front fork•Check operation and for oil leakage.√√√√
15 * Shock absorber assembly•Check operation and shock absorber for oil leakage.√√√√
16 * Carburetor•Adjust engine idling speed.√√√√√ √
17 * Autolube pump•Check operation.
√√√√
•Bleed if necessary.
18 Final transmission oil•Check vehicle for oil leakage.√√ √•Change.√√√
19 * V-belt•Replace. Every 10,000 km
20 * Front and rear brake
•Check operation.√√√√√ √
switches
ODOMETER READING (x 1,000 km)
NO. ITEMCHECK OR MAINTENANCE JOB
1
ANNUAL
CHECK
6121824
6-3

PERIODIC MAINTENANCE AND MINOR REPAIR
6 If the spark plug shows signs of
electrode erosion and excessive
carbon or other deposits, it should be
replaced.
Specified spark plug:
BR8HS (NGK)
Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Spark plug gap:
0.6 — 0.7 mmClean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
Tightening torque:
Spark plug:
23 Nm (2.3 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.
a
ZAUM0037
a Spark plug gap
EAU04228
Final transmission oil
The final transmission case must be
checked for oil leakage before each
ride. If any leakage is found, have a
Yamaha dealer check and repair the
scooter. In addition, the final transmis-
sion oil must be changed as follows at
the intervals specified in the periodic
maintenance and lubrication chart.
1. Start the engine, warm it up by
riding the scooter for several mi-
nutes, and then stop the engine.
2. Place the scooter on the
centerstand.
3. Place an oil pan under the final
transmission case to collect the
used oil.
6-6

PERIODIC MAINTENANCE AND MINOR REPAIR
64. Remove the oil filler cap and drain
bolt to drain the oil from the final
transmission case.
5. Install the final transmission oil
drain bolt, and then tighten it to
the specified torque.
Tightening torque:
Final transmission oil drain bolt:
17 Nm (1.7 m
•kg)
6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten the
oil filler cap.Recommended final transmission oil:
See page 8-1.
Oil quantity:
0.11 L
EWA00062
•Make sure that no foreign
material enters the final trans-
mission case.
•Make sure that no oil gets on
the tire or wheel.
7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
1
2
ZAUM0371
1. Oil filler cap
2. Oil drain bolt
EAUM0071
Cleaning the air filter element
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more
frequently if you are riding in unusually
wet or dusty areas.
1. Remove the air filter case cover
by removing the screws.
1
ZAUM0372
1. Screws
6-7

PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00732
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 level is low, be sure to check the
brake pads for wear and the brake
system for leakage.Observe these precautions:
•When checking the fluid level,
make sure that the top of the
master cylinder is level by turning
the handlebars.
•Use only the recommended
quality brake fluid, otherwise the
rubber seals may deteriorate,
causing leakage and poor braking
performance.
Recommended brake fluid:
DOT 4
NOTE :
If DOT 4 is not available, DOT 3 can be
used.
•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 master cylinder 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.
1
ZAUM0377
1. Brake fluid level
6-14