OWNER’S MANUAL YP400W LIT-11626-20-31 5RU-28199-12
EAU10041
INTRODUCTION EAU10090 Congratulations on your purchase of the Yamaha YP400W. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this scooter.
IMPORTANT MANUAL INFORMATION EAU35821 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the scooter operator, a bystander, or a person inspecting or repairing the scooter. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the scooter.
IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE YP400W OWNER’S MANUAL ©2006 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan.
TABLE OF CONTENTS SAFETY INFORMATION ...................1-1 Further safe-riding points .................1-4 Location of important labels .............1-6 DESCRIPTION ...................................2-1 Left view ...........................................2-1 Right view .........................................2-2 Controls and instruments..................2-3 INSTRUMENT AND CONTROL FUNCTIONS ........................................3-1 Main switch/steering lock .................
TABLE OF CONTENTS Replacing the license plate light bulb ............................................6-38 Troubleshooting .............................6-39 Troubleshooting charts ..................6-40 SCOOTER CARE AND STORAGE ...........................................7-1 Care .................................................7-1 Storage ............................................7-3 SPECIFICATIONS ..............................8-1 CONSUMER INFORMATION..............9-1 Identification numbers ..............
SAFETY INFORMATION EAU10261 1 SCOOTERS ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS SCOOTER. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF SCOOTER OPERATION. THE WARNINGS ● OBSERVE AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
SAFETY INFORMATION Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control. The operator should keep both hands on the handlebar and both feet on the footboard during operation to maintain control of the scooter. The passenger should always hold onto the operator, the seat strap or grab bar, if equipped, with both hands and keep both feet on the passenger footrests.
SAFETY INFORMATION 1 When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the scooter as possible. Make sure to distribute the weight as evenly as possible on both sides of the scooter to minimize imbalance or instability. ● Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely attached to the scooter before riding. Check accessory mounts and cargo restraints frequently.
SAFETY INFORMATION Take care not to spill any gasoline on the engine or exhaust system when refueling. Never refuel while smoking or in the vicinity of an open flame. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your scooter in an area that has adequate ventilation.
SAFETY INFORMATION ● 1 and ankle so they do not flap), and a bright colored jacket. Do not carry too much luggage on the scooter. An overloaded scooter is unstable.
SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
SAFETY INFORMATION 1 4 CAUTION 1 Cleaning with alkaline or acid cleaner, gasoline or solvent will damage windshield. Use neutral detergent. 3JJ—2835Y—A0 2 WARNING BEFORE YOU OPERATE THIS VEHICLE, READ THE OWNER’S MANUAL AND ALL LABELS. ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET, eye protection, and protective clothing. 5RU-21668-00 5 5GK-2118K-00 WARNING Improper loading can cause loss of control. Read owner’s manual for proper loading.
SAFETY INFORMATION 7 1 5RU-21686-00 1-8
DESCRIPTION EAU10410 Left view 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 11 1. Headlight (page 6-36) 2. Fuel tank cap (page 3-9) 3. Rear storage compartment (page 3-13) 4. V-belt case air filter element (page 6-20) 5. Owner’s tool kit (page 6-2) 6. Fuses (page 6-34) 7. Battery (page 6-33) 8. Air filter element (left) (page 6-20) 10 9 9. Engine oil filter element (page 6-14) 10. Centerstand (page 6-31) 11.
DESCRIPTION EAU10420 Right view 1 2 4 3 2 3 4 5 6 7 6 5 1. Grab bar (page 5-2) 2. Passenger seat (page 3-11) 3. Rider seat (page 3-11) 4. Coolant reservoir (page 6-18) 5. Radiator 6.
DESCRIPTION EAU10430 Controls and instruments 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 12 1. Rear brake lever (page 3-8) 2. Left handlebar switches (page 3-6) 3. Rear brake lock lever (page 3-8) 4. Speedometer (page 3-2) 5. Multi-function display (page 3-3) 6. Tachometer (page 3-3) 7. Right handlebar switches (page 3-6) 8. Front brake lever (page 3-7) 11 10 9 9. Throttle grip (page 6-23) 10. Front storage compartment B (page 3-13) 11. Main switch/steering lock (page 3-1) 12.
INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock sidestand is moved down. EAU10660 OFF All electrical systems are off. The key can be removed. loss of control or an accident. Make sure that the vehicle is stopped before turning the key to “OFF” or “LOCK”. 2 EAU10680 The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below.
INSTRUMENT AND CONTROL FUNCTIONS EAU11003 Indicator and warning lights 1 2 3 1 2 3 4 5 6 7 8 9 1. Turn signal indicator lights “ ” and “ 2. High beam indicator light “ ” 3. Engine trouble warning light “ ” EAU11480 Engine trouble warning light “ ” This warning light comes on when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the self-diagnosis system. The electrical circuit of the warning light can be checked by turning the key to “ON”.
INSTRUMENT AND CONTROL FUNCTIONS EAU11872 Tachometer EAU36104 1 Multi-function display 2 3 4 EWA12311 1 2 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function display. 1 2 3 1. Tachometer 2. Tachometer red zone The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range.
INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 ● ● ● ● ● cator started flashing) a self-diagnosis device a clock an ambient temperature display an oil change indicator a V-belt replacement indicator NOTE: ● Be sure to turn the key to “ON” before using the “SELECT” and “RESET” buttons. ● When the key is turned to “ON”, all of the display segments of the multi-function display will appear one after the other and then disappear, in order to test the electrical circuit.
INSTRUMENT AND CONTROL FUNCTIONS vehicle and let the engine cool. (See page 6-40.) ECA10020 CAUTION: Do not operate the engine if it is overheated. Oil change indicator “OIL” This indicator flashes at the initial 1000 km (600 mi), then at 5000 km (3000 mi) and every 5000 km (3000 mi) thereafter to indicate that the engine oil should be changed. After changing the engine oil, reset the oil change indicator. (See page 6-14.) If the engine oil is changed before the oil change indicator comes on (i.e.
INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 Clock mode To set the clock: 1. Push the “SELECT” button and “RESET” button together for at least two seconds. 2. When the hour digits start flashing, push the “RESET” button to set the hours. 3. Push the “SELECT” button, and the minute digits will start flashing. 4. Push the “RESET” button to set the minutes. 5. Push the “SELECT” button and then release it to start the clock.
INSTRUMENT AND CONTROL FUNCTIONS Right EAU12500 Horn switch “ ” Press this switch to sound the horn. 1 EAU12900 Front brake lever 1 EAU12660 Engine stop switch “ / ” Set this switch to “ ” before starting the engine. Set this switch to “ ” to stop the engine in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck. 2 1. Engine stop switch “ / 3 ” EAU12720 2.
INSTRUMENT AND CONTROL FUNCTIONS EAU12950 Rear brake lever EAU12962 Rear brake lock lever ● 1 1 1 2 3 4 5 6 7 8 9 1. Rear brake lever The rear brake lever is located on the left handlebar grip. To apply the rear brake, pull this lever toward the handlebar grip. 1. Rear brake lock lever This vehicle is equipped with a rear brake lock lever to prevent the rear wheel from moving while stopped at traffic signals, railroad crossings, etc.
INSTRUMENT AND CONTROL FUNCTIONS move it. 3. Close the lid. EAU13161 Fuel tank cap 1 To open the fuel tank cap 1. Open the lid by sliding the lever forward, and then pull the lever up. 1 EWA11120 WARNING Be sure that the fuel tank cap is properly installed and locked before riding the scooter. 2 3 1. Fuel tank cap 2 To install the fuel tank cap 1. Align the match marks, insert the fuel tank cap into the tank opening, and then push down on the cap. 1. Lid 2. Opening lever 4 5 6 2.
INSTRUMENT AND CONTROL FUNCTIONS EAU13211 Fuel fuel may deteriorate painted surfaces or plastic parts. EAU36080 1 3 Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity: 14.0 L (3.70 US gal) (3.08 Imp.gal) 1 2 2 ECA11400 4 5 6 1. Fuel tank filler tube 2. Fuel level Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. CAUTION: Use only unleaded gasoline.
INSTRUMENT AND CONTROL FUNCTIONS EAU13431 Catalytic converter EAU34140 Seats This model is equipped with a catalytic converter in the exhaust system. 1 1 EWA10860 WARNING The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work. 3 1. Open. ECA10700 CAUTION: The following precautions must be observed to prevent a fire hazard or other damages. ● Use only unleaded gasoline.
INSTRUMENT AND CONTROL FUNCTIONS 1 To close the rider seat 1. 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 left unattended. 3 NOTE: Make sure that the rider seat is properly secured before riding. 4 Passenger seat 2 5 6 7 To install the passenger seat 1. Insert the projections on the passenger seat into the holders as shown, place the passenger seat in the original position, and then install the bolt.
INSTRUMENT AND CONTROL FUNCTIONS EAU14492 Storage compartments and then remove it. 1 1 1 1. Bolt 3. Slide the rider seat forward or backward to the desired position. 4. Install bolts and securely tighten them. 5. Close the rider seat. Front storage compartment A To open the storage compartment when it is locked, insert the key in the lock, turn it counterclockwise, and then grasp the lock while pushing the button in.
INSTRUMENT AND CONTROL FUNCTIONS 1 ● 1 1 2 3 4 5 ECA11100 2 1. Storage compartment opening lever 2. Lid 1. Rider seat ECA10080 To close the storage compartment, push the lid into the original position. EWA11160 6 WARNING Do not store heavy items in this compartment. 7 8 9 being washed, wrap any articles stored in the compartment in a plastic bag. Do not keep anything valuable or breakable in the storage compartment.
INSTRUMENT AND CONTROL FUNCTIONS EAU15301 Sidestand pair it if it does not function properly. The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright. EAU15371 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch and brake light switches) has the following functions. ● It prevents starting when the sidestand is up, but neither brake is applied.
INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Keep the front or rear brake applied. 5. Push the start switch. Does the engine start? NO NOTE: This check is most reliable if performed with a warmed-up engine. The sidestand switch may be defective. The scooter should not be ridden until checked by a Yamaha dealer. YES With the engine still off: 6.
PRE-OPERATION CHECKS EAU15591 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.
PRE-OPERATION CHECKS EAU15605 Pre-operation check list ITEM CHECKS ● 1 Fuel ● ● 2 ● Engine oil ● ● 3 Final transmission oil ● ● Coolant 4 ● ● ● ● 5 ● Front brake ● ● 6 ● ● ● 7 ● ● 8 Rear brake ● ● ● 9 ● ● Throttle grip ● ● Check fuel level in fuel tank. Refuel if necessary. Check fuel line for leakage. Check oil level in engine. If necessary, add recommended oil to specified level. Check vehicle for oil leakage. Check vehicle for oil leakage. Check coolant level in reservoir.
PRE-OPERATION CHECKS ITEM CHECKS ● Wheels and tires ● ● ● Brake levers Centerstand, sidestand Chassis fasteners Instruments, lights, signals and switches Sidestand switch ● ● ● ● ● ● ● ● ● ● Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. Make sure that operation is smooth. Lubricate lever pivoting points if necessary. Make sure that operation is smooth. Lubricate pivots if necessary. Make sure that all nuts, bolts and screws are properly tightened.
OPERATION AND IMPORTANT RIDING POINTS EAU15980 EAU34460 Starting the engine 1 ● 2 3 4 ● 5 6 7 8 9 ● EWA10870 ECA10250 WARNING 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 fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time.
OPERATION AND IMPORTANT RIDING POINTS EAU16760 Starting off EAU16780 Acceleration and deceleration 1. Close the throttle completely. 2. Apply both front and rear brakes simultaneously while gradually increasing the pressure. NOTE: Before starting off, allow the engine to warm up. 1. While pulling the rear brake lever with your left hand and holding the grab bar with your right hand, push the scooter off the centerstand.
OPERATION AND IMPORTANT RIDING POINTS Rear cult. EAU16841 Engine break-in There is never a more important period in the life of your engine than the period between 0 and 1600 km (1000 mi). 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 1600 km (1000 mi). The various parts in the engine wear and polish themselves to the correct operating clearances.
OPERATION AND IMPORTANT RIDING POINTS nal transmission oil and the oil filter element. 1600 km (1000 mi) and beyond The vehicle can now be operated normally. EAU17212 Parking When parking, stop the engine, and then remove the key from the main switch. EWA10310 ECA10310 CAUTION: ● Keep the engine speed out of the tachometer red zone. ● If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU17271 1 2 3 4 5 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of scooter inspection, adjustment, and lubrication are explained on the following pages. Maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified (if applicable).
PERIODIC MAINTENANCE AND MINOR REPAIR EAU17501 NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. Owner’s tool kit 1 EWA10350 2 1. Storage compartment mat 2. Owner’s tool kit WARNING Modifications not approved by Yamaha may cause loss of performance and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes. 2 3 4 5 The owner’s tool kit is located inside the rear storage compartment.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU17600 Periodic maintenance chart for the emission control system INITIAL 1 No. ITEM ROUTINE 2 ● 1 * Fuel line 3 ● ● 4 2 Spark plug 5 3 * Valve clearance 6 4 * Crankcase breather system 5 * Fuel injection 7 6 * Evaporative emission control system 8 ● ● ● ● ● ● ● ● ● 7 * Air induction system 9 ● Check fuel and vacuum hoses for cracks or damage. Replace if necessary. Check condition. Adjust gap and clean.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU32183 General maintenance and lubrication chart INITIAL No. 1 2 ITEM Air filter elements V-belt case air filter element 3 * Front brake ROUTINE ● Replace. ● Clean. ● Check operation, fluid level, and for fluid leakage. Replace brake pads if necessary. Check operation, fluid level, and for fluid leakage. Replace brake pads if necessary. Check for cracks or damage. Replace. Check operation. Adjust. Check runout and for damage. Replace if necessary.
PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 1 ● 2 10 * Steering bearings ● 3 ● 11 * Chassis fasteners ● 4 12 Front and rear brake lever pivot 13 Centerstand and sidestand pivots 5 ● 6 7 ● 14 * Sidestand switch ● ● ● 15 * Front fork 8 9 ● 16 * Shock absorber assemblies ● ● ● 17 Engine oil ● Check bearing assemblies for looseness. Moderately repack with lithium-soap-based grease. Check all chassis fitting and fasteners. Correct if necessary.
PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. 18 ITEM Engine oil filter element ROUTINE ● Replace. ● ● Check coolant level and vehicle for coolant leakage. Change. Check vehicle for oil leakage. Change. Replace. ● Check operation.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU36370 1 NOTE: ● The air filters and V-belt filter need more frequent service if you are riding in unusually wet or dusty areas. ● Hydraulic brake service After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required. Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU18712 1 1 Removing and installing cowlings and panels The cowlings and panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be removed and installed. 2 1 3 4 2 2 3 1. Cowling D 1. Quick fastener 2. Cowling A 4 EAU34281 Cowling A 6 1. Panel A 2. Cowling C 3. Cowling A 4. Cowling B 5. Panel B 6. Cowling E 5 To remove the cowling 1.
PERIODIC MAINTENANCE AND MINOR REPAIR To install the cowling Place the cowling in the original position, and then install the screws. Cowling B To remove the cowling 1. Remove the screws. 1 2 1 3 4 2 5 6 1 Cowlings C and D 1. Cowling B 2. Screw To remove one of the cowlings 1. Remove cowlings A and B. 2. Remove the passenger seat. (See page 3-11.) 3. Remove the grab bar by removing the grab bar bolts and collars. 3 1 1. Screw access cover 5. Remove the screws, and then pull the cowling off.
PERIODIC MAINTENANCE AND MINOR REPAIR 2 1 1 3 2. Install the screw access cover by placing it in its original position. 3. Install the grab bar by installing the collars and grab bar bolts. 1. Left floorboard mat 2. Remove the cowling screws. Tightening torque: Grab bar bolt: 23 Nm (2.3 m·kgf, 16.6 ft·lbf) 1. Cowling E To install the cowling 1. Insert the tabs on the cowling into the slots as shown, and then install the screws. 5 6 4. Install the passenger seat. 5. Install cowlings A and B.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU34290 Panel A 1 To install the panel Place the panel in the original position, and then install the bolts. 1 To remove the panel 1. Remove the bolts. 2 2 2 3 1. Panel B 2. Screw 4 5 6 7 Panel B 1 1. Bolt 2. Panel A To remove the panel Remove the screws, and then pull the panel outward. To install the panel Place the panel in the original position, and then install the screws. 2 2. Pull the panel out as shown. 8 9 1 1. Screw 2.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU34171 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plug can reveal the condition of the engine. To remove the spark plug 1. Open the rider seat. (See page 3-11.) 2.
PERIODIC MAINTENANCE AND MINOR REPAIR Specified spark plug: NGK/CR7E 1 2 3 To install the spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. 4 5 6 spark plug wrench, and then tighten it to the specified torque. 1 Tightening torque: Spark plug: 12.5 Nm (1.25 m·kgf, 9 ft·lbf) 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.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU36110 Canister EAU34181 Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element replaced at the intervals specified in the periodic maintenance and lubrication chart and when the oil change indicator comes on. This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere.
PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 To change the engine oil (with or without oil filter element replacement) 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place an oil pan under the engine to collect the used oil. 3. Remove the engine oil filler cap and the engine oil drain bolt to drain the oil from the crankcase. 4 1 2 1. Engine oil drain bolt 2. Washer 1 NOTE: Skip steps 5–7 if the oil filter element is not being replaced. 5 6 5.
PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 Tightening torque: Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 3 4 NOTE: Make sure that the O-rings are properly seated. 8. Install the washer and the engine oil drain bolt, and then tighten the drain bolt to the specified torque. 1. Oil filter element cover 2. O-ring 3. Compression spring 4. Oil filter element Tightening torque: Engine oil drain bolt: 20 Nm (2.0 m·kgf, 14.
PERIODIC MAINTENANCE AND MINOR REPAIR 2. Hold the “OIL CHANGE” button pushed for two to eight seconds. releasing the “OIL CHANGE” button, otherwise repeat the procedure. 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 transmission oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart. 1.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU20070 EWA11310 1 ● 2 ● 1. Final transmission oil filler cap 2. Final transmission oil drain bolt WARNING Make sure that no foreign material enters the final transmission 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. 5. Install the final transmission oil drain bolt, and then tighten it to the specified torque.
PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: The coolant should be between the minimum and maximum level marks. 1 1 5. If the coolant is at or below the minimum level mark, open the coolant reservoir cap, add coolant to the maximum level mark, and then close the coolant reservoir cap. 2 3 1. Right floorboard mat 4 3. Remove the coolant reservoir cover by removing the screw. 1 2 3 5 2 6 1 7 1. Minimum level mark 2. Maximum level mark 3. Coolant reservoir cap 8 9 1. Screw 2.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU34203 NOTE: ● The radiator fan is automatically switched on or off according to the coolant temperature in the radiator. ● If the engine overheats, see page 6-40 for further instructions. Air filter elements and check hoses and V-belt case air filter element The air filter elements and the V-belt case air filter element should be serviced at the intervals specified in the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR Left Left 6. Install the rubber cap. ECA12922 1 1 2 3 4 1. Air filter element Right 5 6 1 To clean the air filter check hoses 1. Check the hose at the bottom of both air filter cases for accumulated dirt or water. 7 8 9 CAUTION: ● Make sure that each filter element is properly seated in its case. ● Always replace both air filter elements at the same time, otherwise poor engine performance or damage to the engine may result.
PERIODIC MAINTENANCE AND MINOR REPAIR Cleaning the V-belt case air filter element 1. Remove cowling E. (See page 6-8.) 2. Remove panel B. (See page 6-8.) 3. Remove the V-belt air filter case cover by removing the screws. 1 2 1 1 1 ECA12940 CAUTION: Make sure that the V-belt filter element is properly seated in its case. 2 1. Screw 2. V-belt case air filter element 1 necessary. 7. Install the V-belt case air filter element by installing the screws. 8.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU21381 Checking the throttle cable free play 1 2 3 1 EAU21401 EAU36131 Valve clearance Tires 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.
PERIODIC MAINTENANCE AND MINOR REPAIR Tire air pressure (measured on cold tires): 0–90 kg (0–198 lb): Front: 200 kPa (29 psi) (2.00 kgf/cm2) Rear: 250 kPa (36 psi) (2.50 kgf/cm2) 90–196 kg (198–432 lb): Front: 200 kPa (29 psi) (2.00 kgf/cm2) Rear: 250 kPa (36 psi) (2.50 kgf/cm2) Maximum load*: 196 kg (432 lb) * Total weight of rider, passenger, cargo and accessories total weight of the cargo, rider, passenger, and accessories (cowling, saddlebags, etc.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU21992 1 2 3 4 5 EWA10580 ● 6 7 8 9 Cast wheels Front tire: Size: 120/80-14M/C 58S Manufacturer/model: IRC/MB67 DUNLOP/D305FL Rear tire: Size: 150/70-13M/C 64S Manufacturer/model: IRC/MB67 DUNLOP/D305L ● WARNING It is dangerous to ride with a worn-out tire. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22011 Accessories and replacement parts been approved by Yamaha. EAU33453 Front and rear brake lever free play EWA10621 WARNING This vehicle is not designed to pull a trailer or to be attached to a sidecar. The accessories or replacement parts you choose for your vehicle should be designed specifically for this model, and they must be securely mounted to maintain the inherent stability of the original design.
PERIODIC MAINTENANCE AND MINOR REPAIR brake system. EAU33473 EWA14211 1 2 3 4 5 6 7 8 9 WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the vehicle. Air in the hydraulic system will diminish the braking performance, which may result in loss of control and an accident.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22390 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. EAU22420 Front brake pads indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set.
PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 5 6 7 8 9 enter the brake system, possibly causing it to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23091 EAU23111 Checking and lubricating the cables Checking and lubricating the throttle grip and cable The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it. The operation of the throttle grip should be checked before each ride.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23211 Checking and lubricating the centerstand and sidestand 1 EAU23271 EWA10740 WARNING If the centerstand or sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. 2 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 Checking the steering ECA10590 CAUTION: If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it. Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 Checking the wheel bearings 1 2 EAU34221 Battery The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. ● ● 1 3 4 5 6 7 ● ● 1. Battery The battery is located behind cowling A. (See page 6-8.
PERIODIC MAINTENANCE AND MINOR REPAIR electrical accessories. er, have a Yamaha charge your battery. dealer EAU34232 Replacing the fuses The main fuse and the fuse box, which contains the fuses for the individual circuits, are located behind cowling A. (See page 6-8.) If a fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off the electrical circuit in question. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. To store the battery 1.
PERIODIC MAINTENANCE AND MINOR REPAIR 2 1 2 3 4 5 6 1 7 1 2 3 4 5 1. Spare main fuse 2. Main fuse 1 2 6 1. Ignition fuse 2. Signaling system fuse 3. Headlight fuse 4. Radiator fan fuse 5. Backup fuse (for odometer and clock) 6. Fuel injection system fuse 7. Spare fuse ECA10640 CAUTION: Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire. 7 8 9 Specified fuses: Main fuse: 40.0 A Ignition fuse: 10.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU34240 EAU24180 Replacing a headlight bulb Tail/brake light This model is equipped with quartz bulb headlights. If a headlight bulb burns out, have a Yamaha dealer replace it and, if necessary, adjust the headlight beam. This model is equipped with an LED type of tail/brake light. If the tail/brake light does not come on, have a Yamaha dealer check it. EAU36121 Replacing a front turn signal light bulb 1. Place the scooter on the centerstand. 2. Remove panel A.
PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 2 2 3 4 5 counterclockwise. 7. To insert a new turn signal light bulb into the socket, push it in, and then turn it clockwise until it stops. 8. Install the socket (together with the bulb) by turning it clockwise. 9. Place the turn signal light unit in the original position, and then install the screws. 1. Screw 2. Front turn signal light unit 5. Remove the socket (together with the bulb) by turning it counterclockwise.
PERIODIC MAINTENANCE AND MINOR REPAIR push it in, and then turn it clockwise until it stops. 6. Install the socket (together with the bulb) by turning it clockwise. 7. Install the cowling removed. EAU34270 Replacing the license plate light bulb 1 1. Remove cowling B. (See page 6-8.) 2. Remove the license plate light cover and license plate light lens by removing the screws. 2 3 1. Bulb 1 2 3 1. License plate light lens 2. License plate light cover 3. Screw 3.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU25880 Troubleshooting 1 2 3 4 5 6 7 8 Although Yamaha scooters receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting charts represent quick and easy procedures for checking these vital systems yourself.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU42130 Troubleshooting charts Starting problems or poor engine performance EWA10840 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. 2 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank. 3 The engine does not start.
PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating EWA10400 ● 1 ● 2 WARNING 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.
SCOOTER CARE AND STORAGE EAU26090 Care While the open design of a scooter reveals the attractiveness of the technology, 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. Frequent 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.
SCOOTER CARE AND STORAGE 1 2 3 4 5 6 7 8 9 After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning.
SCOOTER CARE AND STORAGE what products to use. EAU36560 Storage Short-term Always store your scooter in a cool, dry place and, if necessary, protect it against dust with a porous cover. ECA10820 CAUTION: ● 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 chemicals are stored.
SCOOTER CARE AND STORAGE 1 2 3 4 5 6 7 8 9 pivoting points of all levers and pedals as well as of the sidestand/ centerstand. 5. Check and, if necessary, correct the tire air pressure, and then lift the scooter so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 6. Cover the muffler outlet with a plastic bag to prevent moisture from entering it. 7. Remove the battery and fully charge it.
SPECIFICATIONS Dimensions: Overall length: 2230 mm (87.8 in) Overall width: 780 mm (30.7 in) Overall height: 1380 mm (54.3 in) Seat height: 750 mm (29.5 in) Wheelbase: 1565 mm (61.6 in) Ground clearance: 120 mm (4.72 in) Minimum turning radius: 2600 mm (102.4 in) Weight: With oil and fuel: 212.0 kg (467 lb) Engine: Engine type: Liquid cooled 4-stroke, DOHC Cylinder arrangement: Forward-inclined single cylinder Displacement: 395.0 cm3 Bore × stroke: 83.0 × 73.0 mm (3.27 × 2.87 in) Compression ratio: 10.
SPECIFICATIONS Operation: Centrifugal automatic type Chassis: 1 2 3 4 5 6 7 8 9 Frame type: Aluminum die-cast and steel tube backbone Caster angle: 27.00 ° Trail: 100.0 mm (3.
SPECIFICATIONS Headlight: Bulb type: Halogen bulb Bulb voltage, wattage × quantity: Headlight: 12 V, 60 W/55.0 W × 2 Tail/brake light: LED Front turn signal/position light: 12 V, 21 W/5.0 W × 2 Rear turn signal light: 12 V, 21.0 W × 2 License plate light: 12 V, 5.0 W × 1 Meter lighting: 12 V, 2.0 W × 3 High beam indicator light: 12 V, 1.4 W × 1 Turn signal indicator light: 12 V, 1.4 W × 2 Engine trouble warning light: 12 V, 1.4 W × 1 Radiator fan fuse: 10.0 A Fuel injection system fuse: 10.
CONSUMER INFORMATION EAU26351 Identification numbers 1 2 3 Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. KEY IDENTIFICATION NUMBER: 4 1 VEHICLE IDENTIFICATION NUMBER: The key identification number is stamped into the key tag. Record this number in the space provided and use it for reference when ordering a new key.
CONSUMER INFORMATION EAU26500 Model label 1 2 3 4 1. Model label The model label is affixed to the inside of the rear storage compartment. (See page 3-13.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
CONSUMER INFORMATION EAU26550 Reporting safety defects 1 2 3 If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
CONSUMER INFORMATION EAU26580 Scooter noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such devi
CONSUMER INFORMATION EAU26632 Maintenance record 1 2 3 4 5 6 7 8 9 Copies of work orders and/or receipts for parts purchased and installed on your vehicle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.
CONSUMER INFORMATION Maintenance interval Date of service Servicing dealer name and address Mileage 32000 mi (49000 km) or 48 months 36000 mi (55000 km) or 54 months 40000 mi (61000 km) or 60 months Remarks 2 3 4 5 6 7 8 9 9-6
CONSUMER INFORMATION EAU26662 YAMAHA MOTOR CORPORATION, U.S.A.
CONSUMER INFORMATION 2 3 4 5 6 7 8 9 9-8
CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). 1 2 3 4 5 6 7 8 In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
CONSUMER INFORMATION We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need. 2 Yamaha Service Marketing P.O.
INDEX A Acceleration and deceleration................... 5-2 Accessories and replacement parts........ 6-26 Air filter elements and check hoses and V-belt case air filter element ................. 6-20 Front fork, checking .................................6-31 Fuel..........................................................3-10 Fuel tank cap .............................................3-9 Fuses, replacing ......................................6-34 H B Battery...............................................
INDEX V Valve clearance .......................................6-23 Vehicle identification number.....................9-1 W Warranty, extended ...................................9-9 Warranty, limited........................................9-7 Wheel bearings, checking .......................6-33 Wheels.....................................................
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2006.5–0.
