Yamaha Aerox 50 owners manual

OWNER’S MANUAL

YQ50 / YQ50L5WJ-F8199-E0

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EAU04576

INTRODUCTION

Welcome to the Yamaha world of motorcycling!

As the owner of the YQ50 or YQ50L, you are benefiting from Yamaha's vast experience and newest technology regardingthe design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.

Please take the time to read this manual thoroughly, so as to enjoy all advantages of your YQ50 or YQ50L. The owner'smanual does not only instruct you in how to operate, inspect and maintain your scooter, but also in how to safeguardyourself and others from trouble and injury.

In addition, the many tips given in this manual will help keep your scooter in the best possible condition. If you have anyfurther questions, do not hesitate to contact your Yamaha dealer.

The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!



EAU00005

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY ISINVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to thescooter operator, a bystander, or a person inspecting or repairing the scooter.

A CAUTION indicates special precautions that must be taken to avoid damage to thescooter.

NOTE : A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE :

• This manual should be considered a permanent part of this scooter and should remain with it even if thescooter is subsequently sold.

• Yamaha continually seeks advancements in product design and quality. Therefore, while this manualcontains the most current product information available at the time of printing, there may be minordiscrepancies between your scooter and this manual. If you have any questions concerning this manual,please consult your Yamaha dealer.



EW000002

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THISSCOOTER.

WARNING

IMPORTANT MANUAL INFORMATION



EAUM0023

YQ50 or YQ50LOWNER'S MANUAL

© 2002 by MBK INDUSTRIE1st Edition, July 2002

All rights reservedAny reprinting or unauthorized usewithout the written permission of

MBK INDUSTRIEis expressly prohibited.

Printed in France.



11 GIVE SAFETY THE RIGHT OF WAY

2 DESCRIPTION

3 INSTRUMENT AND CONTROL FUNCTIONS

4 PRE-OPERATION CHECKS

5 OPERATION AND IMPORTANT RIDING POINTS

6 PERIODIC MAINTENANCE AND MINOR REPAIR

7 SCOOTER CARE AND STORAGE

8 SPECIFICATIONS

9 CONSUMER INFORMATION

EAU00009

TABLE OF CONTENTS

2

3

4

5

6

7

8

9





GIVE SAFETY THE RIGHT OF WAY .................................................. 1-1Further safe-riding points .................................................................... 1-2

EAU00021EW000015

GIVE SAFETY THE RIGHT OF WAY

1




1

Scooters are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However,they also impose certain limits, which you must accept; even the best scooter does not ignore the laws ofphysics.

Regular care and maintenance are essential for preserving value and operating condition of your scooter.Moreover, what is true for the scooter is also true for the rider: good performance depends on being in goodshape. Riding under the influence of medication, drugs and alcohol is, of course, out of the question. Scooterriders—more than car drivers—must always be at their mental and physical best. Under the influence ofeven small amounts of alcohol, there is a tendency to take dangerous risks.

Protective clothing is as essential for the scooter rider as seat belts are for car drivers and passengers.Always wear a complete scooter suit (whether made of leather or tear-resistant synthetic materials withprotectors), sturdy boots, scooter gloves and a properly fitting helmet. Optimum protective wear, however,should not encourage carelessness. Although full-coverage helmets and suits, in particular, create an illu-sion of total safety and protection, motorcyclists will always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is even more dangerous in wet weather.The good motorcyclist rides safely, predictably and defensively — avoiding all dangers, including thosecaused by others.

Enjoy your ride!

1-1




1

EAU03099

Further safe-riding points• Be sure to signal clearly when making turns.

• Braking can be extremely difficult on a wet road. Avoid hard braking, because the scooter could slide.Apply the brakes slowly when stopping on a wet surface.

• Slow down as you approach a corner or turn. Once you have completed a turn, accelerate slowly.

• Be careful when passing parked cars. A driver might not see you and open a door in your path.

• Railroad crossings, streetcar rails, iron plates on road construction sites, and manhole covers becomeextremely slippery when wet. Slow down and cross them with caution. Keep the scooter upright, otherwiseit could slide out from under you.

• The brake pads could get wet when you wash the scooter. After washing the scooter, check the brakesbefore riding.

• Always wear a helmet, gloves, trousers (tapered around the cuff and ankle so they do not flap), and abright colored jacket.

• Do not carry too much luggage on the scooter. An overloaded scooter is unstable.

1-2





EAU01161

DESCRIPTION

Left view .............................................................................................. 2-1Right view............................................................................................ 2-2

2



2

DESCRIPTION

Left view

1. Rear brake lever (page 3-5, 6-13, 6-16)2. Left handlebar switches (page 3-4)3. Speedometer (page 3-3)4. Main switch/steering lock (page 3-1, 3-9)

2-1

1 2 3 4

6

8

7 5

5. Final transmission oil filler cap (page 6-7)6. Centerstand (page 6-16)7. Kick starter (page 3-7)8. Air filter (page 6-9)



2

DESCRIPTION

Right view

9 10

14

11

12

13

9. Throttle grip (page 6-11)10. Front brake lever (page 3-5, 6-13, 6-16)11. Coolant tank location (page 6-8)12. Battery/fuse (page 6-18 - 6-20)

2-2

13. Oil tank cap location (page 3-8)14. Fuel tank cap (page 3-5)





EAU00027

INSTRUMENT AND CONTROL FUNCTIONS

Main switch / steering lock .................................................................. 3-1Indicator and warning lights ................................................................ 3-2Coolant temperature warning light ...................................................... 3-2Speedometer unit ................................................................................ 3-3Tachometer (depends on model) ........................................................ 3-3Fuel gauge .......................................................................................... 3-3Handlebar switches ............................................................................. 3-4Front brake lever ................................................................................. 3-5Rear brake lever .................................................................................. 3-5Fuel tank cap ...................................................................................... 3-5Fuel ..................................................................................................... 3-6Catalytic converter .............................................................................. 3-7Kick starter .......................................................................................... 3-72-stroke engine oil tank cap ................................................................ 3-82-stroke engine oil ............................................................................... 3-8Starter (choke) lever ............................................................................ 3-9Rider seat ............................................................................................ 3-9Storage compartment A .................................................................... 3-10Storage compartment B .................................................................... 3-11Adjusting the shock absorber assembly (depends on model) ........... 3-11

3



3


EAU00029

Main switch/steering lockThe main switch/steering lock controlsthe ignition and lighting systems, andis used to lock the steering. The variouspositions are described below.

PUSH

OPEN

ZAUM0253

EAU00038

OFF “ ”All electrical systems are off. The keycan be removed.

EAU04470

CHECK “ ”The 2-stroke engine oil level warninglight should come on. See page 3-2 foran explanation of the engine oil levelwarning light.

EAU00040

LOCK “ ”The steering is locked, and all electricalsystems are off. The key can beremoved.

To lock the steering1. 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 steeringPush the key in, and then turn it to “ ”while still pushing it.

EW000016

Never turn the key to “ ” or “ ”while the scooter is moving, otherwisethe electrical systems will be switchedoff, which may result in loss of controlor an accident. Make sure that the scoo-ter is stopped before turning the keyto “ ” or “ ”.

WARNING

3-1

EAU00037

ON “ ”All electrical circuits are supplied withpower, and the engine can be started.The key cannot be removed.

NOTE :The headlight, meter lighting andtaillight come on automatically when theengine is started.




3

EAU03034

Indicator and warning lights

TEMP

1 2 3ZAUM0254

1. Turn signal indicator light “ ”2. High beam indicator light “ ”3. Oil indicator light “ ”

EAU00057

Turn signal indicator light “ ”This indicator light flashes when theturn signal switch is pushed to the leftor right.

EAU00063

High beam indicator light “ ”This indicator light comes on when thehigh beam of the headlight is switchedon.

EAU02958

Oil level warning light “ ”This warning light comes on when thekey is in the “ ” position or when theoil level in the 2-stroke engine oil tankis low during operation. If the warninglight comes on during operation, stopimmediately and fill the oil tank withYamalube 2 or equivalent 2-strokeengine oil of either JASO grade "FC"or ISO grades "EG-C" or "EG-D". Thewarning light should go off after the 2-stroke engine oil tank has been refilled.

NOTE :If the warning light does not come onwhen the key is in the “ ” position ordoes not go off after the 2-stroke engineoil tank has been refilled, have a Yamahadealer check the electrical circuit.

EC000000

Do not operate the scooter until youknow that the engine oil level issufficient.

CAUTION:

EAU01716

Coolant temperature warning light“ ”This warning light comes on when theengine overheats. When this occurs,stop the engine immediately and allowthe engine to cool.

EC000002

Do not operate the engine if it isoverheated.

CAUTION:

TEMP

1ZAUM0255

1. Coolant temperature warning light “ ”

3-2



3


EAU00098

Speedometer unitThe speedometer unit is equipped witha speedometer and an odometer. Thespeedometer shows riding speed. Theodometer shows the total distancetraveled.

EAU00113

Fuel gaugeThe fuel gauge indicates the amount offuel in the fuel tank. The needle movestowards "E" (Empty) as the fuel leveldecreases. When the needle reaches"E", refuel as soon as possible.

NOTE :Do not allow the fuel tank to empty itselfcompletely.

E

1/2

F1

ZAUM0257

1. Speedometer2. Odometer

1. Fuel gauge

3-3

1 2

ZAUM0292M

1. Tachometer2. Red zone

EAU00101

Tachometer(Depends on model)The electric tachometer allows the ri-der to monitor the engine speed andkeep it within the ideal power range.

EC000003

Do not operate the engine in thetachometer red zone.

Red zone: 10.000 r/min and above

CAUTION:

2

1

ZAUM0291M

UK ONLY




3

EAU00118

Handlebar switches

EAU03888

Dimmer switch “ / ”Set this switch to “ ” for the high beamand to “ ” for the low beam.

EAU03889

Turn signal switch “ / ”To signal a right-hand turn, push this switchto “ ”. To signal a left-hand turn, push thisswitch to “ ”. When released, the switchreturns to the center position. To cancel theturn signal lights, push the switch in after ithas returned to the center position.

EAU00129

Horn switch “ ”Press this switch to sound the horn.

EAUM0063

Start switch “ ”Push this switch while applying the frontor rear brake to crank the engine withthe starter.

EC000005

See page 5-2 for starting instruc-tions prior to starting the engine.

1

2

3

ZAUM0258

1ZAUM0261

1. Horn switch “ ”2. Turn signal switch “ / ”3. Dimmer switch “ / ”

CAUTION:

1. Start switch “ ”

3-4



3


EAU03882

Front brake leverThe front brake lever is located on theright handlebar grip. To apply the frontbrake, pull this lever toward thehandlebar grip.

EAU00163

Rear brake leverThe rear brake lever is located on theleft handlebar grip. To apply the rearbrake, pull this lever toward thehandlebar grip.

1. Front brake lever 1. Rear brake lever

1

ZAUM0084

1

ZAUM0085

EAU02935*

Fuel tank capTo open the fuel tank capOpen the fuel tank cap lock cover, insertthe key into the lock, and then turn it 1/4turn counterclockwise. The lock will bereleased and the fuel tank cap can beopened.

1

ZAUM0262

3-5

1. Fuel tank cap




3

To close the fuel tank cap1. Push the fuel tank cap into posi-

tion with the key inserted in thelock.

2. Turn the key clockwise to the ori-ginal position, remove it, and thenclose the lock cover.

NOTE :The fuel tank cap cannot be closedunless the key is in the lock. In addi-tion, the key cannot be removed if thecap is not properly closed and locked.

EWA00025

Make sure that the fuel tank cap isproperly closed before riding.

WARNING

EAU03753

FuelMake sure that there is sufficient fuelin the tank. Fill the fuel tank to thebottom of the filler tube as shown.

EW000130

• Do not overfill the fuel tank,otherwise it may overflow whenthe fuel warms up and expands.

• Avoid spilling fuel on the hotengine.

WARNING

1

2

ZAUM0020

1. Filler tube2. Fuel level

EAU00185EC000008

Immediately wipe off spilled fuel witha clean, dry, soft cloth, since fuel maydeteriorate painted surfaces or plas-tic parts.

CAUTION:

EAU04206

Recommended fuel:REGULAR UNLEADEDGASOLINE ONLY

Fuel tank capacity:Total amount:

7 L

Your Yamaha engine has beendesigned to use regular unleadedgasoline with a research octanenumber of 91 or higher. If knocking (orpinging) occurs, use a gasoline of adifferent brand or premium unleadedfuel. Use of unleaded fuel will extendspark plug life and reduce maintenancecosts.

3-6



3

INSTRUMENT AND CONTROL FUNCTIONSEAU03098

Catalytic converterThis scooter is equipped with a catalyticconverter in the muffler.

EW000128

The exhaust system is hot afteroperation. Make sure that theexhaust system has cooled downbefore doing any maintenance work.

EC000114

The following precautions must beobserved to prevent a fire hazard orother damages.

• Use only unleaded gasoline.The use of leaded gasoline willcause unrepairable damage tothe catalytic converter.

• Never park the scooter nearpossible fire hazards such asgrass or other materials thateasily burn.

• Do not allow the engine to idletoo long.

WARNING

CAUTION:

3-7

ZAUM0289M

EAUS0015

KickstarterTo start the engine, push the kickstarterdown lightly with your foot until thegears engage, and then push it downsmoothly but forcefully.




3ZAUM0204

1

2ZAUM0263

1. Storage compartment B2. Oil tank cap

3-8

EAU03750

2-stroke engine oilMake sure that there is sufficient oil inthe 2-stroke engine oil tank. Add therecommended 2-stroke engine oil ifnecessary.

NOTE :Make sure that the 2-stroke engine oiltank cap is properly installed.

Recommended oil:Yamalube 2or equivalent 2-stroke engine oil(JASO grade "FC", or ISOgrades "EG-C" or "EG-D")

Oil quantity:1.3 L

EAUM0082

2-stroke engine oil tank capThe 2-stroke engine oil tank cap islocated in the storage compartment.(See page 3-11 for storagecompartment opening and closingprocedures.)

1. To remove the 2-stroke engine oiltank cap, pull it off.

2. To install the 2-stroke engine oiltank cap, push it into the oil tankopening.

NOTE :Make sure that the 2-stroke engine oiltank cap is properly installed beforeriding the scooter.



3


EAU03091

Rider seatTo open the rider seat

1. Place the scooter on thecenterstand.

2. Insert the key into the main switch,and then turn it counterclockwise.

NOTE :Do not push inward when turning thekey.

3. Fold the rider seat up.

To close the rider seat1. Fold the rider seat down, and then

push it down to lock it in place.2. Remove the key from the main

switch if the scooter will be leftunattended.

NOTE :Make sure that the seat is properlysecured before riding.

1

ZAUM0264

1. Seat

3-9

EAU03839

Starter (choke) lever " "Starting a cold engine requires a richerair-fuel mixture, which is supplied by thestarter (choke).

• Move the lever in direction a toturn on the starter (choke).

• Move the lever in direction b toturn off the starter (choke).

1. Starter (choke) lever " "

ab

1

ZAUM0293




3

1

ZAUM0265

1. Storage compartment A

EAU03450

Storage compartment AThere is a storage compartment underthe seat. (See page 3-9 for seat openingand closing procedures.)

EWA00005

• Do not exceed the load limit of 3.0kg for the storage compartment.

• Do not exceed the maximumload of 180 kg for the vehicle.(Load is the totalweight of rider,passenger, cargo and acces-sories.)

EC000010

Keep the following points in mindwhen using the storage compartment.

• Since the storage compartmentaccumulates heat whenexposed to the sun, do not storeanything susceptible to heatinside it.

• To avoid humidity fromspreading through the storagecompartment, wrap wet articlesin a plastic bag before storingthem in the compartment.

• Since the storage compartmentmay get wet while the scooteris being washed, wrap any arti-cles stored in the compartmentin a plastic bag.

• Do not keep anything valuableor breakable in the storagecompartment.

To store a helmet in the storagecompartment, place the helmet upside-down with the front facing forward.

NOTE :

• Some helmets cannot be storedin the storage compartmentbecause of their size or shape.

• Do not leave your scooterunattended with the seat open.

CAUTION:

WARNING

3-10



3


a

1

ZAUM0266

1. Storage compartment locka Open

3-11

ba

12

ZAUM0294

EAU00295

Adjusting the shock absor-ber assembly(depends on model)This shock absorber assembly isequipped with a spring preloadadjusting ring.

EC000015

Never attempt to turn an adjustingmechanism beyond the maximum orminimum settings.

Adjust the spring preload as follows.

• To increase the spring preload andthereby harden the suspension,turn the adjusting ring in directiona .

• To decrease the spring preloadand thereby soften the suspen-sion, turn the adjusting ring in di-rection b .

NOTE :Align the appropriate notch in theadjusting ring with the position indicatoron the shock absorber.

CAUTION:

Setting

Minimum (soft) b

Standard middle

Maximum (hard) a

1. Spring preload adjusting ring2. Position indicator

EAUM0083

Storage compartment BThe storage compartment is located infront of the seat.

To open the storage compartment1. Insert the key into the lock, and

then turn it clockwise.2. Fold the storage compartment

cover up.

To close the storage compartment1. Fold the storage compartment

cover down.2. Turn the key counterclockwise,

and then remove it.




3

EAU00315EW000041

This shock absorber contains highlypressurized nitrogen gas. For properhandling, read and understand thefollowing information beforehandling the shock absorber. Themanufacturer cannot be heldresponsible for property damage orpersonal injury that may result fromimproper handling.

• Do not tamper with or attemptto open the gas cylinder.

• Do not subject the shock absor-ber to an open flame or otherhigh heat sources, otherwise itmay explode due to excessivegas pressure.

• Do not deform or damage thegas cylinder in any way, as thiswill result in poor damping per-formance.

• Always have a Yamaha dealerservice the shock absorber.

WARNING

3-12





EAU01114

PRE-OPERATION CHECKS

Pre-operation check list ....................................................................... 4-1

4




4

EAU03439

Pre-operation check list

ITEM CHECKS PAGE

• 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.Two-stroke engine oil • If necessary, add recommended oil to specified level. 3-8, 6-15

• Check vehicle for oil leakage.

Final transmission oil • Check vehicle for oil leakage. 6-7

• Check coolant level in reservoir.Coolant • If necessary, add recommended coolant to specified level. 6-8

• Check cooling system for leakage.

• Check operation.• If soft or spongy, have Yamaha dealer bleed hydraulic system.

Front brake • Check fluid level in reservoir. 3-5, 6-13 — 6-15• 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. 3-5, 6-13 — 6-15• If necessary, add recommended brake fluid to specified level.• Check hydraulic system for leakage.

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 orloss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visualinspection, to check the following points before each ride.

4-1



4


ITEM CHECKS PAGE

• Make sure that operation is smooth.

Throttle grip• Check cable free play.

6-11• If necessary, have Yamaha dealer adjust cable free play

and lubricate cable and grip housing.

• Check for damage.

Wheels and tires• Check tire condition and tread depth.

6-11 — 6-13• Check air pressure.• Correct if necessary.

Brake levers• Make sure that operation is smooth.

6-13, 6-16• Lubricate lever pivoting points if necessary.

Centerstand• Make sure that operation is smooth.

6-16• Lubricate pivot if necessary.

Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.

—• Tighten if necessary.

Instruments, lights • Check operation.3-3, 3-4, 6-20 — 6-22signals and switches • Correct if necessary.

Battery• Check fluid level.

6-18• Fill with distilled water if necessary.

4-2




4

NOTE :Pre-operation checks should be made each time the scooter is used. Such an inspection can be accomplished in a veryshort time; and the added safety it assures is more than worth the time involved.

EWA00033

If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operatingthe scooter.

WARNING

4-3



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OPERATION AND IMPORTANT RIDING POINTS

Starting the engine .............................................................................. 5-1Starting a warm engine ....................................................................... 5-2Starting off ........................................................................................... 5-2Acceleration and deceleration ............................................................. 5-3Braking ................................................................................................ 5-3Tips for reducing fuel consumption ..................................................... 5-4Engine break-in ................................................................................... 5-4Parking ................................................................................................ 5-5

5




5

EAU01118EW000129

• Become thoroughly familiarwith all operating controls andtheir functions before riding.Consult a Yamaha dealerregarding any control orfunction that you do notthoroughly understand.

• Never start the engine oroperate it in a closed area forany length of time. Exhaust fu-mes are poisonous, andinhaling them can cause loss ofconsciousness and deathwithin a short time. Alwaysmake sure that there isadequate ventilation.

• For safety, always start theengine with the centerstanddown.

WARNING

CAUTION:

CAUTION:

PUSH

OPEN

ZAUM0253

5-1

EAU00415*

Starting the engine1. Turn the key to " ", then when the

oil level warning light comes on,turn it to " ".

EC000045

If the oil level warning light does notcome on, have a Yamaha dealercheck the electrical circuit.

2. Turn the starter (choke) on andcompletely close the throttle. (Seepage 3-9 for starter (choke)operation.)

3. Start the engine by pushing thestart switch or by pushing thekickstarter lever down, whileapplying the front or rear brake.

NOTE :If the engine fails to start by pushingthe start switch, release the switch, waita few seconds, and then try again. Eachstarting attempt should be as short aspossible to preserve the battery. Do notcrank the engine more than 5 secondson any one attempt. If the engine doesnot start with the starter motor, try usingthe kickstarter.

4. After starting the engine, move thestarter (choke) lever back halfway.

ECA00045

For maximum engine life, neveraccelerate hard when the engine iscold!




5

EAU00433

Starting off

NOTE :Before starting off, allow the engine towarm up.

1. While pulling the rear brake leverwith your left hand and holding thegrab bar with your right hand,push the scooter off thecenterstand.

2. Sit astride the seat, and thenadjust the rear view mirrors.

3. Switch the turn signal on.4. Check for oncoming traffic, and

then slowly turn the throttle grip(on the right) in order to take off.

5. Switch the turn signal off.

ZAUM0267

5-2

5. When the engine is warm, turn thestarter (choke) off.

NOTE :The engine is warm when it respondsnormally to the throttle with the starter(choke) turned off.

EAU01258

Starting a warm engineFollow the same procedure as forstarting a cold engine with the excep-tion that the starter (choke) is notrequired when the engine is warm.




5

EAU00435

Braking1. Close the throttle completely.2. Apply both front and rear brakes

simultaneously while graduallyincreasing the pressure.

EW000057

• Avoid braking hard or suddenly(especially when leaning overto one side), otherwise thescooter may skid or overturn.

• Railroad crossings, streetcarrails, iron plates on road cons-truction sites, and manholecovers become extremelyslippery when wet. Therefore,slow down when approachingsuch areas and cross them withcaution.

• Keep in mind that braking on awet road is much more difficult.

• Ride slowly down a hill, asbraking downhill can be verydifficult.

ZAUM0269

WARNING

5-3

EAU00434

Acceleration anddecelerationThe speed can be adjusted by openingand closing the throttle. To increase thespeed, turn the throttle grip in directiona . To reduce the speed, turn the throttlegrip in direction b .

B A

a

b

ZAUM0268




5

EAU00436

Engine break-inThere is never a more important periodin the life of your engine than the periodbetween 0 and 1,000 km. For thisreason, you should read the followingmaterial carefully.

Since the engine is brand new, do notput an excessive load on it for the first1,000 km. The various parts in theengine wear and polish themselves tothe correct operating clearances.During this period, prolonged full-throttle operation or any condition thatmight result in engine overheating mustbe avoided.

EAUT0003

0 — 150 kmAvoid operation above 1/3 throttle. Stopthe engine and let it cool for 5 to 10minutes after every hour of operation.Vary the speed of the scooter from timeto time. Do not operate it at one setthrottle position.

150 — 500 kmAvoid prolonged operation above 1/2throttle.

500 — 1,000 kmAvoid cruising speeds in excess of 3/4 throttle.

ECAT0001

After 1,000 km of operation, be sureto replace the final transmission oil.

1,000 km and beyondAvoid prolonged full throttle operation.Vary speeds occasionally.

EC000049

If any engine trouble should occurduring the engine break-in period,immediately have a Yamaha dealercheck the vehicle.

CAUTION:

CAUTION:

5-4

EAU03093

Tips for reducing fuelconsumptionFuel consumption depends largely onyour riding style. Consider the followingtips to reduce fuel consumption:

• Thoroughly warm up the engine.

• Avoid high engine speeds duringacceleration.

• Avoid high engine speeds with noload on the engine.

• Turn the engine off instead ofletting it idle for an extended lengthof time (e.g., in traffic jams, attraffic lights or at railroadcrossings).




5

EAU00461

ParkingWhen parking, stop the engine, andthen remove the key from the mainswitch.

EW000058

• Since the engine and exhaustsystem can become very hot,park in a place wherepedestrians or children are notlikely to touch them.

• Do not park on a slope or onsoft ground, otherwise thescooter may overturn.

EC000062

Never park in an area where thereare fire hazards such as grass orother flammable materials.

WARNING

CAUTION:

5-5



EAU00462

PERIODIC MAINTENANCE AND MINOR REPAIR

Periodic maintenance and lubrication chart ............ 6-2Removing and installing cowling and panel ............ 6-5Cowling A ................................................................ 6-5Panel A .................................................................... 6-5Checking the spark plug ......................................... 6-6Final transmission oil .............................................. 6-7Coolant .................................................................... 6-8Cleaning the air filter element ................................. 6-9Adjusting the carburetor ........................................ 6-10Adjusting the throttle cable free play ..................... 6-11Tires ...................................................................... 6-11Wheels .................................................................. 6-13Adjusting the front and rear brake leverfree play ................................................................ 6-13Checking the front and rear brake pads ................ 6-14Checking the brake fluid level ............................... 6-14

6

Changing the brake fluid ....................................... 6-15Adjusting the autolube pump ................................ 6-15Checking and lubricating the cables ..................... 6-16Lubricating the front and rear brakes levers .......... 6-16Checking and lubricating the centerstand ............. 6-16Checking the front fork .......................................... 6-17Checking the steering ........................................... 6-17Checking the wheel bearings ................................ 6-18Battery................................................................... 6-18Replacing the fuse ................................................ 6-20Replacing a headlight bulb .................................... 6-20Replacing tail/brake light bulb ............................... 6-21Replacing a turn signal light bulb .......................... 6-22Troubleshooting ..................................................... 6-22Troubleshooting chart ............................................ 6-23Engine overheating ............................................... 6-24




6

EAU03453

Safety is an obligation of the owner.Periodic inspection, adjustment andlubrication will keep your vehicle in thesafest and most efficient condition pos-sible. The most important points ofscooter inspection, adjustment, andlubrication are explained on thefollowing pages.

EW000060

If you are not familiar with scootermaintenance work, have a Yamahadealer do it for you.

EAU00466EW000061

This scooter is designed for use onpaved roads only. If this scooter isoperated in abnormally dusty,muddy or wet conditions, the air filterelement should be cleaned orreplaced more frequently, otherwiserapid engine wear may result.Consult a Yamaha dealer for propermaintenance intervals.WARNING

WARNING

6-1




6

1 * Fuel line • Check fuel hoses and vacuum hose for cracks or damage. √ √ √ √ √2 Spark plug • Replace. √ √ √ √ √

3 Air filter element• Clean. √ √• Replace. √ √

4 * Battery• Check electrolyte level and specific gravity.

√ √ √ √ √• Make sure that the breather hose is properly routed.

• Check operation, fluid level and vehicle for fluid leakage.√ √ √ √ √ √5 * Front brake (See NOTE on page 6-4.)

• Replace brake pads. Whenever worn to the limit

• Check operation, fluid level and vehicle for fluid leakage.√ √ √ √ √ √6 * Rear brake (See NOTE on page 6-4.)

• Replace brake pads. Whenever worn to the limit

7 * Brake hoses• Check for cracks or damage. √ √ √ √ √

• Replace. (See NOTE on page 6-4.) Every 4 years

8 * Wheels • Check runout and for damage. √ √ √ √

EAU03686

Periodic maintenance and lubrication chartNOTE :

• The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.

• From 30,000 km, repeat the maintenance intervals starting from 6,000 km.

• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

ODOMETER READING (x 1,000 km)

NO. ITEM CHECK OR MAINTENANCE JOB 1ANNUALCHECK6 12 18 24

6-2




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• Check starter (chocke) operation.

√ √ √ √ √ √• 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



6-3




6

EAU03541*

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.

21 Moving parts and cables • Lubricate. √ √ √ √ √

22 *Lights, signals • Check operation.

√ √ √ √ √ √and switches • Adjust headlight beam.



6-4




6

EAU03810

Removing and installing thecowling and panelThe cowling and panel shown aboveneed to be removed to perform someof the maintenance jobs described inthis chapter. Refer to this section eachtime a cowling or panel needs to beremoved and installed.

1

2

ZAUM0270

1. Cowling A2. Panel A

EAU00482

Cowling ATo remove the cowlingRemove the screws, and then take thecowling off.

To install the cowlingPlace the cowling in the original posi-tion, and then install the screws.

1

ZAUM0271

1. Screws

2

1

ZAUM0272

1. Panel A2. Screw

6-5

EAUM0084

Panel ATo remove the panel

1. Open the storage compartment.(See page 3-11 for storagecompartment opening and closingprocedures.)

2. Remove the screw, and then takethe panel off.

To install the panel1. Place the panel in the original po-

sition, and then install the screw.2. Close the storage compartment.




6

EAU01651

Checking the spark plugThe spark plug is an important enginecomponent, which should be checkedperiodically, preferably by a Yamahadealer. Since heat and deposits willcause any spark plug to slowly erode,it should be removed and checked inaccordance with the periodic mainte-nance and lubrication chart. In addition,the condition of the spark plug canreveal the condition of the engine.The porcelain insulator around thecenter electrode of the spark plugshould be a medium-to-light tan (theideal color when the scooter is riddennormally). If the spark plug shows adistinctly different color, the enginecould be defective. Do not attempt todiagnose such problems yourself.Instead, have a Yamaha dealer checkthe scooter.If the spark plug shows signs ofelectrode erosion and excessive carbonor other deposits, it should be replaced.

Specified spark plug:BR8HS (NGK)

Before installing a spark plug, the sparkplug gap should be measured with awire thickness gauge and, if necessary,adjusted to specification.

Spark plug gap:0.5 — 0.7 mm

Clean the surface of the spark pluggasket and its mating surface, and thenwipe off any grime from the spark plugthreads.

a

ZAUM0037

a Spark plug gap

Tightening torque:Spark plug:

20 Nm (2.0 m•kg)

NOTE :If a torque wrench is not available wheninstalling a spark plug, a good estimateof the correct torque is 1/4—1/2 turnpast finger tight. However, the sparkplug should be tightened to thespecified torque as soon as possible.

6-6




6

EWA00062

• Make sure that no foreignmaterial enters the final trans-mission case.

• Make sure that no oil gets onthe tire or wheel.

7. Check the final transmission casefor oil leakage. If oil is leaking,check for the cause.

WARNING

EAU04228

Final transmission oilThe final transmission case must bechecked for oil leakage before eachride. If any leakage is found, have aYamaha dealer check and repair thescooter. In addition, the final transmis-sion oil must be changed as follows atthe intervals specified in the periodicmaintenance and lubrication chart.

1. Start the engine, warm it up byriding the scooter for several mi-nutes, and then stop the engine.

2. Place the scooter on thecenterstand.

3. Place an oil pan under the finaltransmission case to collect theused oil.

4. Remove the oil filler cap and drainbolt to drain the oil from the finaltransmission case.

5. Install the final transmission oildrain bolt, and then tighten it tothe specified torque.

Tightening torque:Final transmission oil drain bolt:

18 Nm (1.8 m•kgf)

6. Add the specified amount of therecommended final transmissionoil, and then install and tighten theoil filler cap.

Recommended final transmissionoil:

See page 8-1.Oil quantity:

0.13 L

1

2

ZAUM0273

1. Final transmission oil drain bolt2. Oil filler cap

6-7




6

EC000080

• If coolant is not available, usedistilled water or soft tap waterinstead. Do not use hard wateror salt water since it is harmfulto the engine.

• If water has been used insteadof coolant, replace it withcoolant as soon as possible,otherwise the engine may notbe sufficiently cooled and thecooling system will not beprotected against frost and cor-rosion.

• If water has been added to thecoolant, have a Yamaha dealercheck the antifreeze content ofthe coolant as soon as possi-ble, otherwise the effectivenessof the coolant will be reduced.

EW000067

Never attempt to remove the radiatorcap when the engine is hot.

CAUTION:

WARNING

EAU01808*

CoolantTo check the coolant level

1. Place the scooter on a level sur-face and hold it in an upright po-sition.

NOTE :

• The coolant level must bechecked on a cold engine sincethe level varies with enginetemperature.

• Make sure that the scooter ispositioned straight up whenchecking the coolant level. A slighttilt to the side can result in a falsereading.

2. Remove cowling A. (See page6-5 for cowling removal and ins-tallation procedures.)

3. Check the coolant level in thecoolant reservoir.

NOTE :The coolant should be between theminimum and maximum level marks.

4. If the coolant is at or below theminimum level mark, open thereservoir cap, add coolant to themaximum level mark, and thenclose the reservoir cap.

Coolant reservoir capacity:0.25 L

�

1

ZAUM0274

1. Coolant tank cap

6-8




6

1

ZAUM0276

1. Air filter element

5. Install the cowling.

NOTE :If the engine overheats, see page 6-24for further instructions.

1

ZAUM0275

1. Screws

EAUM0071

Cleaning the air filterelementThe air filter element should be cleanedat the intervals specified in the periodicmaintenance and lubrication chart.Clean the air filter element morefrequently if you are riding in unusuallywet or dusty areas.

1. Remove the air filter case coverby removing the screws.

2. Pull the air filter element out, cleanit with solvent, and then squeezethe remaining solvent out.

EW000075

Use only a dedicated parts cleaningsolvent. To avoid the risk of fire orexplosion, do not use gasoline orsolvents with a low flash point.

EC000089

To avoid damaging the foam material,handle it gently and carefully, and donot twist or wring it.

WARNING

CAUTION:

6-9




6

1

43

2

ZAUM0156

3. Apply oil of the recommendedtype to the entire surface of theelement, and then squeeze theexcess oil out.

NOTE :The air filter element should be wet butnot dripping.

Recommended oil:Engine oil

4. Insert the element into the air filtercase.

CAUTION:EC000082

• Make sure that the air filterelement is properly seated inthe air filter case.

• The engine should never beoperated without the air filterelement installed, otherwise thepiston(s) and/or cylinder(s) maybecome excessively worn.

5. Install the air filter case cover byinstalling the screws.

6-10

EAU00631

Adjusting the carburetorThe carburetor is an important part ofthe engine and requires verysophisticated adjustment. Therefore, allcarburetor adjustments should be leftto a Yamaha dealer, who has thenecessary professional knowledge andexperience.




6

EAU04551

TiresTo maximize the performance,durability, and safe operation of yourscooter, note the following pointsregarding the specified tires.

Tire air pressureThe tire air pressure should be checkedand, if necessary, adjusted before eachride.

EW000082

• The tire air pressure must bechecked and adjusted on coldtires (i.e., when the temperatureof the tires equals the ambienttemperature).

• The tire air pressure must beadjusted in accordance with theriding speed and with the totalweight of rider, passenger,cargo, and accessoriesapproved for this model.

WARNING

01

2

3

4

ZAUM0053

Tire air pressure(measured on cold tires)

Load* Front Rear

Up to 90 kg*150 kPa1.5 kgf/cm2

1.5 bar

150 kPa1.5 kgf/cm2

1.5 bar

90 kg ~maximum*

150 kPa1.5 kgf/cm2

1.5 bar

170 kPa1.7 kgf/cm2

1.7 bar

Maximum load* 180 kg

* Total weight of rider, passenger, cargo and accessories

6-11

a

ZAUM0051

EAU00635

Adjusting the throttle cablefree playThe throttle cable free play shouldmeasure 1.0 — 3.0 mm at the throttlegrip. Periodically check the throttle cablefree play and, if necessary, have aYamaha dealer adjust it.

a Throttle cable free play




6

Tire inspectionThe tires must be checked before eachride. If the center tread depth reachesthe specified limit, if the tire has a nailor glass fragments in it, or if the sidewallis cracked, have a Yamaha dealer re-place the tire immediately.

1

2

ZAUM0054

1. Tread depth2. Side wall

Tire informationThis scooter is equipped with tubelesstires.

Minimum tire tread depth (front and rear)

1.6 mm

NOTE :The tire tread depth limits may differfrom country to country. Always complywith the local regulations.

FrontManufacturer Size Type

PIRELLIM 130/60-13M SL36

RearManufacturer Size Type

MICHELINM 130/60-13M BOPPER

PIRELLIM 130/60-13M EVO 21

PIRELLIM 140/60-13M SL36

MICHELINM 140/60-13M BOPPER

PIRELLIM 140/60-13 M EVO 22

6-12

EW000077

Because loading has an enormousimpact on the handling, braking, per-formance and safety characteristics ofyour scooter, you should keep thefollowing precautions in mind.

• NEVER OVERLOAD THE SCOO-TER! Operation of an overloadedscooter may result in tire damage,loss of control, or severe injury.Make sure that the total weight ofrider, cargo, and accessoriesdoes not exceed the specifiedmaximum load for the vehicle.

• Do not carry along looselypacked items, which can shiftduring a ride.

• Securely pack the heaviest itemsclose to the center of the scooterand distribute the weight evenlyon both sides.

• Adjust the suspension and tire airpressure with regard to the load.

• Check the tire condition and airpressure before each ride.

WARNING




6

EAUM0056

Adjusting the front and rearbrake lever free playThe front and rear brake lever free playshould measure 10 — 20 mm as shown.Periodically check the front and rearbrake lever free play and, if necessary,have a Yamaha dealer adjust it.

EW000100

An incorrect brake lever free playindicates a hazardous condition inthe brake system. Do not operate thescooter until the brake system hasbeen checked or repaired by aYamaha dealer.

WARNING

a

ZAUM0107

a

ZAUM0108

a Front brake lever free play a Rear brake lever free play

6-13

EAU03773

Cast wheelsTo maximize the performance,durability, and safe operation of yourscooter, note the following pointsregarding the specified wheels.

• The wheel rims should bechecked for cracks, bends orwarpage before each ride. If anydamage is found, have a Yamahadealer replace the wheel. Do notattempt even the smallest repairto the wheel. A deformed orcracked wheel must be replaced.

• The wheel should be balancedwhenever either the tire or wheelhas been changed or replaced. Anunbalanced wheel can result inpoor performance, adversehandling characteristics, and ashortened tire life.

• Ride at moderate speeds afterchanging a tire since the tire surfacemust first be "broken in" for it todevelop its optimal characteristics.




6

EAU00717

Checking the front and rearbrake pads

The front and rear brake pads must bechecked for wear at the intervalsspecified in the periodic maintenanceand lubrication chart. To check thebrake pad wear, measure the liningthickness. If the lining thickness is lessthan 2.0 mm, have a Yamaha dealerreplace the brake pads as a set.

a

ZAUM0277

a

ZAUM0278

a Brake pad thickness a Brake pad thickness

EAU00732

Checking the brake fluidlevelInsufficient brake fluid may allow air toenter the brake system, possiblycausing it to become ineffective.Before riding, check that the brake fluidis above the minimum level mark andreplenish if necessary. A low brake fluidlevel may indicate worn brake pads and/or brake system leakage. If the brakelevel is low, be sure to check the brakepads for wear and the brake system forleakage.

1 1

ZAUM0280

1. Brake fluid minimum level

6-14




6

Observe these precautions:

• When checking the fluid level,make sure that the top of themaster cylinder is level by turningthe handlebars.

• Use only the recommendedquality brake fluid, otherwise therubber seals may deteriorate,causing leakage and poor brakingperformance.

Recommended brake fluid:DOT 4

NOTE :If DOT 4 is not available, DOT 3 can beused.

• Refill with the same type of brakefluid. Mixing fluids may result in aharmful chemical reaction andlead to poor braking performance.

• Be careful that water does notenter the master cylinder whenrefilling. Water will significantlylower the boiling point of the fluidand may result in vapor lock.

• Brake fluid may deterioratepainted surfaces or plastic parts.Always clean up spilled fluidimmediately.

• As the brake pads wear, it is nor-mal for the brake fluid level togradually go down. However, if thebrake fluid level goes downsuddenly, have a Yamaha dealercheck the cause.

EAUM0008*

Changing the brake fluidHave a Yamaha dealer change thebrake fluid at the intervals specified inthe periodic maintenance andlubrication chart. In addition, have thebrake hoses replaced every four yearsor whenever there are damaged orleaking.

6-15

EAU00774

Adjusting the Autolube pumpThe Autolube pump is a vital andsophisticated component of the engine,which must be adjusted by a Yamahadealer at the intervals specified in theperiodic maintenance and lubricationchart.




6

ZAUM0061

EAU03118

Lubricating the front and rearbrake leversThe pivoting points of the front and rearbrake levers must be lubricated at theintervals specified in the periodic main-tenance and lubrication chart.

Recommended lubricant:Lithium-soap-based grease(all-purpose grease)

ZAUM0062

EAU04123

Checking and lubricating thecenterstandThe operation of the centerstand shouldbe checked before each ride, and thepivots and metal-to-metal contact sur-faces should be lubricated if necessary.

EWA00055

If the centerstand does not move upand down smoothly, have a Yamahadealer check or repair it.

Recommended lubricant:Lithium-soap-based grease(all-purpose grease)

WARNING

6-16

EAU02962

Checking and lubricating thecablesThe operation of all control cables andthe condition of the cables should bechecked before each ride, and the cablesand cable ends should be lubricated ifnecessary. If a cable is damaged or doesnot move smoothly, have a Yamaha dea-ler check or replace it.

Recommended lubricant:Engine oil

EW000112

Damage to the outer sheath mayinterfere with proper cable operationand will cause the inner cable to rust.Replace a damaged cable as soonas possible to prevent unsafe con-ditions.

WARNING




6

EAU02939

Checking the front forkThe condition and operation of the frontfork must be checked as follows at theintervals specified in the periodic main-tenance and lubrication chart.

To check the condition

EW000115

Securely support the scooter so thatthere is no danger of it falling over.

Check the inner tubes for scratches,damage and excessive oil leakage.

WARNING To check the operation1. 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 thehandlebars several times to checkif the front fork compresses andrebounds smoothly.

EC000098

If any damage is found or the frontfork does not operate smoothly, havea Yamaha dealer check or repair it.

CAUTION:

EAU00794

Checking the steeringWorn or loose steering bearings maycause danger. Therefore, the operationof the steering must be checked asfollows at the intervals specified in theperiodic maintenance and lubricationchart.

1. Place a stand under the engineto raise the front wheel off theground.

EW000115

Securely support the scooter so thatthere is no danger of it falling over.

WARNING

6-17

ZAUM0296 ZAUM0297




6

EAU01144

Checking the wheel bearingsThe front and rear wheel bearings mustbe checked at the intervals specified inthe periodic maintenance andlubrication chart. If there is play in thewheel hub or if the wheel does not turnsmoothly, have a Yamaha dealer checkthe wheel bearings.

1

ZAUM0281

1. Battery

EAUM0049

BatteryA poorly maintained battery will corrodeand discharge quickly. The electrolytelevel, battery lead connections andbreather hose routing should bechecked before each ride and at theintervals specified in the periodic main-tenance and lubrication chart.

To check the electrolyte level1. Place the scooter on a level sur-

face and hold it in an upright posi-tion.

NOTE :Make sure that the scooter is positionedstraight up when checking theelectrolyte level.

2. Remove panel A. (See page 6-5for panel removal and installationprocedures.)

3. Check the electrolyte level in thebattery.

NOTE :The electrolyte should be between theminimum and maximum level marks.

12+UPPER

LOWER

ZAUM0106

1. Maximum level2. Minimum level

6-18

2. Hold the lower ends of the frontfork legs and try to move themforward and backward. If any freeplay can be felt, have a Yamahadealer check or repair thesteering.




6

4. If the electrolyte is at or below theminimum level mark, add distilledwater to raise it to the maximumlevel mark.

EW000116

• Electrolyte is poisonous anddangerous since it containssulfuric acid, which causessevere burns. Avoid any con-tact with skin, eyes or clothingand always shield your eyeswhen working near batteries. Incase of contact, administer thefollowing FIRST AID.• EXTERNAL: Flush with

plenty of water.• INTERNAL: Drink large

quantities of water or milkand immediately call aphysician.

• EYES: Flush with water for 15minutes and seek promptmedical attention.

• Batteries produce explosivehydrogen gas. Therefore, keepsparks, flames, cigarettes, etc.,away from the battery andprovide sufficient ventilationwhen charging it in an enclosedspace.

• KEEP THIS AND ALL BATTE-RIES OUT OF THE REACH OFCHILDREN.

EC000100

Use only distilled water, as tap watercontains minerals that are harmfulto the battery.

5. Check and, if necessary, tightenthe battery lead connections andcorrect the breather hose routing.

WARNING

CAUTION:

To store the battery1. If the scooter will not be used for

more than one month, remove thebattery, fully charge it, and thenplace it in a cool, dry place.

2. If the battery will be stored formore than two months, check thespecific gravity of the electrolyteat least once a month and fullycharge the battery whenevernecessary.

3. Fully charge the battery beforeinstallation.

4. After installation, make sure thatthe battery leads are properlyconnected to the battery terminalsand that the breather hose isproperly routed, in good condition,and not obstructed.

EC000099

If the breather hose is positioned insuch a way that the frame is exposedto electrolyte or gas expelled fromthe battery, the frame could sufferstructural and external damages.

CAUTION:

6-19




6

1

ZAUM0282

1. Fuse

EAU01307

Replacing the fuseThe fuse holder is located behind pa-nel A. (See page 6-5 for panel removaland installation procedures.)

If the fuse is blown, replace it as follows.1. Turn the key to " " and turn off

all electrical circuits.2. Remove the blown fuse, and then

install a new fuse of the specifiedamperage.

Specified fuse: 7.5 A

EC000103

Do not use a fuse of a higheramperage rating than recommendedto avoid causing extensive damageto the electrical system and possiblya fire.

3. Turn the key to " " and turn onthe electrical circuits to check if thedevices operate.

4. If the fuse immediately blowsagain, have a Yamaha dealercheck the electrical system.

CAUTION:

EAUM0072*

Replacing a headlight bulb1. Remove cowling A

(See page 6-5 for cowling removaland installation procedures.)

2. Remove the headlight coupler.3. Remove the headlight bulb holder by

turning it 1/4 turn counterclockwise.4. Remove the defective bulb.

EW000119

Headlight bulbs get very hot.Therefore, keep flammable productsaway from a lit headlight bulb, anddo not touch the bulb until it hascooled down.

1

ZAUM0283

1. Headlight bulb

WARNING

6-20




6

5. Place a new headlight bulb intoposition, and then secure it withthe bulb holder.

6. Connect the headlight couplerand install the cowling A.

EC000105

Do not touch the glass part of theheadlight bulb to keep it free fromoil, otherwise the transparency ofthe glass, the luminosity of the bulb,and the bulb life will be adverselyaffected. Thoroughly clean off anydirt and fingerprints on the headlightbulb using a cloth moistened withalcohol or thinner.

CAUTION:

ZAUM0284

6-21

EAUM0037

Replacing the brake/taillightbulb

1. Remove the brake/taillight lens byremoving the screws.

2. Remove the brake/taillight bulbholder by turning it 1/4 turncounter-clockwise.

3. Remove the defective bulb.4. Place a new bulb into position, and

then secure it with the bulb holder.5. Place the brake/taillight lens in the

original position, and then installthe screw.




6

ZAUM0285 ZAUM0286

EAU03218

Replacing a turn signal lightbulb

1. Remove the turn signal lens byremoving the screws.

2. Remove the defective bulb bypushing it in and turning itcounterclockwise.

3. Insert a new bulb into the socket,push it in, and then turn itclockwise until it stops.

4. Install the lens by installing thescrews.

EC000108

Do not overtighten the screws,otherwise the lens may break.

CAUTION:

EAU03087

TroubleshootingAlthough Yamaha scooters receive athorough inspection before shipmentfrom the factory, trouble may occurduring operation. Any problem in thefuel, compression, or ignition systems,for example, can cause poor startingand loss of power.

The following troubleshooting chartsrepresent quick and easy proceduresfor checking these vital systemsyourself. However, should your scooterrequire any repair, take it to a Yamahadealer, whose skilled technicians havethe necessary tools, experience, andknow-how to service the scooterproperly.

Use only genuine Yamaha replacementparts. Imitation parts may look likeYamaha parts, but they are ofteninferior, have a shorter service life andcan lead to expensive repair bills.

6-22




6

EAU03363

Troubleshooting chartsStarting problems or poor engine performance

EW000125

Keep away open flames and do not smoke while checking or working on the fuel system.

WARNING

Check the fuel level inthe fuel tank.

1. FuelThere is enough fuel.

There is no fuel.

Check the compression.

Supply fuel.

Operate the electric starter.

2. CompressionThere is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealercheck the vehicle.

Remove the spark plugsand check the electrodes.

3. IgnitionWet

Dry

Wipe off with a dry cloth and correct the spark plug gaps, or replace the spark plugs.

Have a Yamaha dealer check the vehicle. The engine does not start.Check the battery.

Open the throttle halfway and operatethe electric starter.

Operate the electric starter.

4. Battery The engine turns over quickly.

The engine turns over slowly.

The battery is good.

Check the electrolyte and batterylead connections, and charge thebattery if necessary.

The engine does not start. Have a Yamaha dealer check the vehicle.

The engine does not start. Check the compressoin.

6-23




6

Engine overheatingEW000070

• Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may beblown 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 thenslowly 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 recommendedcoolant as soon as possible.

WARNING

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 systemfor 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 isleakage.

There is no leakage.

6-24





EAU03434

SCOOTER CARE AND STORAGE

Care .................................................................................................... 7-1Storage ............................................................................................... 7-3

7




7

CareWhile the open design of a scooterreveals the attractiveness of thetechnology, it also makes it morevulnerable. Rust and corrosion candevelop even if high-qualitycomponents are used. A rusty exhaustpipe may go unnoticed on a car,however, it detracts from the overallappearance of a scooter. Frequent andproper care does not only comply withthe terms of the warranty, but it will alsokeep your scooter looking good, extendits life and optimize its performance.

Before cleaning1. Cover the muffler outlet with a

plastic bag after the engine hascooled down.

2. Make sure that all caps and coversas well as all electrical couplersand connectors, including thespark plug cap, are tightlyinstalled.

3. Remove extremely stubborn dirt,like oil burnt onto the crankcase,with a degreasing agent and abrush, but never apply suchproducts onto seals, gaskets andwheel axles. Always rinse the dirtand degreaser off with water.

CleaningECA00011

• Avoid using strong acidic wheelcleaners, especially on spokedwheels. If such products areused on hard-to-remove dirt, donot leave the cleaner on theaffected area any longer thaninstructed. Also, thoroughlyrinse the area off with water,immediately dry it, and thenapply a corrosion protectionspray.

• Improper cleaning can damagewindshields, cowlings, panelsand other plastic parts. Useonly a soft, clean cloth orsponge with mild detergent andwater to clean plastic.

CAUTION:

7-1




7

• Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been incontact with strong or abrasivecleaning products, solvent orthinner, fuel (gasoline), rustremovers or inhibitors, brakefluid, antifreeze or electrolyte.

• Do not use high-pressurewashers or steam-jet cleanerssince they cause waterseepage and deterioration inthe following areas: seals (ofwheel and swingarm bearings,fork and brakes), electriccomponents (couplers,connectors, instruments,switches and lights), breatherhoses and vents.

• For scooters equipped with awindshield: Do not use strongcleaners or hard sponges asthey will cause dulling orscratching. Some cleaningcompounds for plastic mayleave scratches on thewindshield. Test the product ona small hidden part of thewindshield to make sure that itdoes not leave any marks. If thewindshield is scratched, use aquality plastic polishingcompound after washing.

After normal useRemove dirt with warm water, a milddetergent, and a soft, clean sponge,and then rinse thoroughly with cleanwater. Use a toothbrush or bottlebrushfor hard-to-reach areas. Stubborn dirtand insects will come off more easily ifthe area is covered with a wet cloth fora few minutes before cleaning.

After riding in the rain, near the seaor on salt-sprayed roadsSince sea salt or salt sprayed on theroads during winter are extremely cor-rosive in combination with water, carryout the following steps after each ridein the rain, near the sea or on salt-sprayed roads.

NOTE :Salt sprayed on roads in the winter mayremain well into spring.

1. Clean the scooter with cold waterand a mild detergent after theengine has cooled down.

ECA00012

Do not use warm water since itincreases the corrosive action of thesalt.

2. Apply a corrosion protection sprayon all metal, including chrome-and nickel-plated, surfaces toprevent corrosion.

CAUTION:

7-2




7

After cleaning1. Dry the scooter with a chamois or

an absorbing cloth.2. Use a chrome polish to shine

chrome, aluminum and stainless-steel parts, including the exhaustsystem. (Even the thermallyinduced discoloring of stainless-steel exhaust systems can beremoved through polishing.)

3. To prevent corrosion, it isrecommended to apply a corro-sion protection spray on all metal,including chrome- and nickel-plated, surfaces.

4. Use spray oil as a universalcleaner to remove any remainingdirt.

5. Touch up minor paint damagecaused by stones, etc.

6. Wax all painted surfaces.7. Let the scooter dry completely

before storing or covering it.

EWA00002

• Make sure that there is no oil orwax on the brakes or tires. Ifnecessary, clean the brake discsand brake linings with a regularbrake disc cleaner or acetone,and wash the tires with warmwater and a mild detergent.

• Before operating the scootertest its braking performance andcornering behavior.

ECA00013

• Apply spray oil and wax sparinglyand make sure to wipe off anyexcess.

• Never apply oil or wax to anyrubber and plastic parts, but treatthem with a suitable care product.

• Avoid using abrasive polishingcompounds as they will wearaway the paint.

NOTE :Consult a Yamaha dealer for advice onwhat products to use.

StorageShort-term

Always store your scooter in a cool, dryplace and, if necessary, protect itagainst dust with a porous cover.

ECA00015

• Storing the scooter in a poorlyventilated room or covering itwith a tarp, while it is still wet,will allow water and humidity toseep in and cause rust.

• To prevent corrosion, avoiddamp cellars, stables (becauseof the presence of ammonia)and areas where strongchemicals are stored.

WARNING

CAUTION:

CAUTION:

7-3




7

Long-termBefore storing your scooter for severalmonths:

1. Follow all the instructions in the"Care" section of this chapter.

2. Drain the carburetor float chamberby loosening the drain bolt; this willprevent fuel deposits from buildingup. Pour the drained fuel into the fueltank.

3. Fill up the fuel tank and add fuelstabilizer (if available) to prevent thefuel tank from rusting and the fuelfrom deteriorating.

4. Perform the following steps to protectthe cylinder, piston rings, etc. fromcorrosion.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 ontothe spark plug, and then placethe spark plug on the cylinderhead so that the electrodes aregrounded. (This will limitsparking during the next step.)

d. Turn the engine over severaltimes with the starter. (This willcoat the cylinder wall with oil.)

e. Remove the spark plug capfrom the spark plug, and theninstall the spark plug and thespark plug cap.

EWA00003

To prevent damage or injury fromsparking, make sure to ground thespark plug electrodes while turningthe engine over.

5. Lubricate all control cables andthe pivoting points of all levers andpedals as well as of the sidestand/centerstand.

6. Check and, if necessary, correctthe tire air pressure, and then liftthe scooter so that both of itswheels are off the ground.Alternatively, turn the wheels alittle every month in order toprevent the tires from becomingdegraded in one spot.

7. Cover the muffler outlet with aplastic bag to prevent moisturefrom entering it.

8. Remove the battery and fullycharge it. Store it in a cool, dryplace and charge it once a month.Do not store the battery in anexcessively cold or warm place(less than 0 °C or more than 30°C). For more information onstoring the battery, see page 6-19.

NOTE :Make any necessary repairs beforestoring the scooter.

WARNING

7-4





EAU01038

SPECIFICATIONS

Specifications ...................................................................................... 8-1Conversion table ................................................................................. 8-4

8



SPECIFICATIONS

8

Specifications

Model YQ50

Dimensions:Overall length 1.743 mmOverall width 690 mmOverall height 1.170 mmSeat height 828 mmWheelbase 1.256 mmMinimum ground clearance 185 mmMinimum turning radius 1.800 mm

Basic weight: 97 kg(with oil and full fuel tank)

Engine:Engine type Liquid cooled, 2 strokeCylinder arrangement Single cylinder, horizontalDisplacement 49.2 ccBore x stroke 40.0 x 39.2Compression ratio 7.44:1Starting system Electric and kick starterLubrication system Separate lubrication (Autolube)

Engine oil:Type Yamalube 2

or 2 stroke engine oilRecommended engine oil Jaso FCclassification or ISO EG-C, EG-DCapacity 1.3 L

Final transmission oil:Type SAE 10W30 type SEQuantity 0.13L

Cooling system capacity: 1.2L(total amount)

Air filter type: Wet type element

Fuel:Recommended fuel Regular unleaded gasoline

(RON 91 mini)Fuel tank capacity 7L

Carburetor:Manufacturer DELL'ORTOModel/quantity PHBN 12HS x1

Spark plug:Manufacturer/Model NGK / BR8HSSpark plug gap 0.5—0.7 mm

Clutch type: Dry, centrifugal automatic

Transmission:Primary reduction system Helical gearPrimary reduction ratio 52/13 (4.000)Secondary reduction system Spur gearSecondary reduction ratio 43/14 (3.071)Transmission type V-belt automaticOperation Centrifugal automatic type

8-1



SPECIFICATIONS

8

Chassis:Frame type Steel tube underboneCaster angle 27°Trail 89.4 mm

Tires:Front:

Type TubelessSize 130/60-13 53L TLManufacturer/ Model PIRELLI / SL36

PIRELLI / EVO 21MICHELIN / BOPPER

Rear:Type TubelessSize 140/60-13 57L TLanufacturer/ Model PIRELLI / SL36

PIRELLI / EVO 22MICHELIN / BOPPER

Maximum load* 180 kgTir air pressure(mesured on cold tires):

Up to 90 kgFront 150 kpaRear 150 kpa

90kg—maximum*Front 150 kpaRear 170 kpa

* Total weight of rider, passenger, cargo and accessories

Wheels:Front

Type Cast wheelSize 13 X MT 3.00

RearType Cast wheelSize 13 X MT 3.50

Brakes:Front

Type Single disc brakeOperation Right hand operationType brake fluid DOT 3 or DOT 4

RearType Single disc brake

Operation Left hand operationType brake fluid DOT 3 or DOT 4

Suspension:Front suspension Telescopic forkRear suspension Unit swing

Shock absorber:Front fork type Coil spring/oil damperRear shock absorber Coil spring/oil damperassembly type or Coil spring/Gas-oil damper

(Depends on model)

Wheel travel:Front wheel travel 80 mmRear wheel travel 72 mm

8-2



SPECIFICATIONS

8

Electrical:Ignition system type C.D.ICharging system Flywheel magnetoBattery

Model GM4-3B, YB4L-B, FB4L-BVoltage/capacity 12 V / 4 Ah

Headlight type: Bulb

Bulbs (voltage/wattage x quantity):Headlight 12V, 35W/35Wx1Brake/brake light 12V, 5W/21Wx1Turn signal light

Front 12V, 10Wx2Rear 12V, 10Wx2

Meter lights 12V, 1,2Wx2High beam indicator light 12V, 2Wx1Turn signal indicator light 12V, 2Wx1Oil warning light 12V, 2Wx1

Temperature indicator light 12V, 1,2Wx1

Fuses:Main fuse 7.5 A

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SPECIFICATIONS

8

EAU04513

Conversion table

All specification data in this manual are listed in SI andMETRIC UNITS.

Use this table to convert METRIC unit values to IMPERIALunit values.

Example:

METRIC VALUE CONVERSION FACTOR

IMPERIAL VALUE

2 mm 0.03937 = 0.08 in

Conversion tableMETRIC SYSTEM TO IMPERIAL SYSTEM

Metric unit Conversion factor Imperial unit

Torque

m•kgfm•kgfcm•kgfcm•kgf

7.233 86.794 0.0723 0.8679

ft•lbfin•lbfft•lbfin•lbf

Weight kgg

2.205 0.03527

lboz

Speed km/h 0.6214 mi/h

Distance

kmmmcmmm

0.6214 3.281 1.094 0.3937 0.03937

miftydinin

Volume,Capacity

cc (cm3)cc (cm3)L (liter)L (liter)

0.03527 0.06102 0.8799 0.2199

oz (IMP liq.)cu•inqt (IMP liq.)gal (IMP liq.)

Miscellaneouskg/mmkgf/cm2

C

55.997 14.2234 1.8 + 32

lb/inpsi (lbf/in2)F

8-4





9

EAU01039

CONSUMER INFORMATION

Identification numbers ......................................................................... 9-1Key identification number .................................................................... 9-1Vehicle identification number .............................................................. 9-1Model label .......................................................................................... 9-2




9

1

ZAUM0070

1

ZAUM0287M

1. Key identification number

EAU01041

Key identification numberThe key identification number isstamped into the key tag.Record this number in the spaceprovided and use it for reference whenordering a new key.

EAU01044

Vehicle identification numberThe vehicle identification number isstamped into the frame.

NOTE :The vehicle identification number isused to identify your scooter and maybe used to register your scooter withthe licensing authority in your area.

1. Vehicle identification number

9-1

EAU02944

Identification numbersRecord the key identification number,vehicle identification number and modellabel information in the spaces providedbelow for assistance when orderingspare parts from a Yamaha dealer orfor reference in case the vehicle isstolen.

1. KEY IDENTIFICATION NUMBER:

2. VEHICLE IDENTIFICATIONNUMBER:

3. MODEL LABEL INFORMATION:




9

9-2

1

ZAUM0295

1. Model label

EAU01278

Model labelThe model label is affixed to the bottomof the seat. (See page 3-9 for seatopening procedures.) Record the infor-mation on this label in the spaceprovided. This information will beneeded when ordering spare parts froma Yamaha dealer.




9

EAU01052

YOU ARE HEREBY REMINDED THAT MODIFICATIONS TO THE ENGINE OR THE POWER OF THE SCOOTER AREFORBIDDEN BY LAW.

ANY CHANGES FOR THE PURPOSE OF RAISING THE TOP SPEED OF THE VEHICLE OR BOOSTING THE POWEROF THE ENGINE WOULD LEAD TO THE SCOOTER BEING CLASSED AS A MOTORCYCLE.

THIS WOULD REQUIRE THE OWNER:

• TO OBTAIN A NEW TYPE APPROVAL

• TO OBTAIN A MOTORCYCLE REGISTRATION LICENSE

• TO HOLD A DRIVING LICENSE

IN ADDITION, SUCH CHANGES WOULD LEAD TO THE INVALIDATION OF TIE INSURANCE COVER, SINCEINSURANCE POLICIES EXPLICITLY FORBID TECHNICAL CHANGES WHICH HAVE THE PURPOSE OF BOOSTINGTHE PERFORMANCE.

FOR THE REASONS SET OUT ABOVE, A BREACH OF THE PROHIBITION TO TAMPER WITH THE ENGINE ISPUNISHED BY LAW BY APPROPRIATE FINES INCLUDING THE CONFISCATION OF THE VEHICLE.

FINES ARE ALSO INFLICTED, ACCORDING TO CIRCUMSTANCES, FOR DRIVING WITHOUT A HELMET AND ALICENSE PLATE, AS WELL AS FOR TAX EVASION (OMITTING TO PAY OWNERSHIP TAX).

DRIVING WITHOUT A DRIVING LICENSE IS A CRIMINAL OFFENSE.

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PRINTED IN FRANCE2002.07 (E)

YAMAHA MOTOR CO., LTD.



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Yamaha Aerox 50 owners manual