Manual Moto

4VP-F8199-E1

YW100E

OWNER’S MANUAL

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Welcome to the Yamaha world of motorcycling!

As the owner of a BW’S100, you are benefiting from Yamaha’s vast experience in and newesttechnology for the design and the manufacture of high-quality products, which have earnedYamaha a reputation for dependability.

Please take the time to read this manual thoroughly, so as to enjoy all your BW’S100’s advan-tages. The owner’s manual does not only instruct you in how to operate, inspect and maintainyour scooter, but also in how to safeguard yourself and others from trouble and injury.

In addition, the many tips given in this manual will help to keep your scooter in the best possiblecondition. If you have any further 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!

INTRODUCTION

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

IMPORTANT MANUAL INFORMATION

NOTE:9 This manual should be considered a permanent part of this scooter and should remain with it

even if the scooter is subsequently sold.9 Yamaha continually seeks advancements in product design and quality. Therefore, while this

manual contains the most current product information available at the time of printing, theremay be minor discrepancies between your scooter and this manual. If there is any questionconcerning this manual, please consult your Yamaha dealer.

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

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

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

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.

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NOTE:

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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS SCOOTER.

IMPORTANT MANUAL INFORMATION

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YW100EOWNER’S MANUAL

© 1999 by Yamaha Motor Taiwan Co., Ltd.1st Edition, March 1999

All rights reserved. Any reprinting orunauthorized use without the written

permission of Yamaha Motor Taiwan Co., Ltd.is expressly prohibited.

Printed in Taiwan

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TABLE OF CONTENTS

GIVE SAFETY THE RIGHT OF WAY.................1-1FURTHER SAFE RIDING POINTS FOR THISMODEL ..............................................................1-2

DESCRIPTION ...................................................2-1Left view ........................................................2-1Right view .....................................................2-2Controls / Instruments .................................2-3

INSTRUMENT AND CONTROLFUNCTIONS ......................................................3-1

Main switch / Steering lock .........................3-1Indicator lights ..............................................3-2Speedometer ................................................3-2Fuel gauge ....................................................3-2Handlebar switches ......................................3-3Front brake lever ..........................................3-4Rear brake lever ...........................................3-4Fuel and oil tanks .........................................3-4Fuel ................................................................3-5Fuel tank breather hose ...............................3-5Two-storoke engine oil ................................3-6Kick starter ....................................................3-6Seat ...............................................................3-6Helmet holder ...............................................3-7Trunk .............................................................3-7Rear carrier ...................................................3-8

Front trunk ....................................................3-8Luggage hook ...............................................3-8Sidestand ......................................................3-8Sidestand switch operation check ..............3-9

PRE-OPERATION CHECKS ...............................4-1Pre-operation check list ...............................4-1

OPERATION AND IMPORTANT RIDINGPOINTS ..............................................................5-1

Starting up a cold engine ............................5-1Starting off ....................................................5-2Acceleration ..................................................5-2Braking ..........................................................5-2Engine break-in ............................................5-2Parking ..........................................................5-3

PERIODIC MAINTENANCE AND MINORREPAIR ..............................................................6-1

Took kit ..........................................................6-1Periodic maintenance and lubrication ........6-3Cowling and panel removal andinstallation ....................................................6-6Cowling A .....................................................6-6Panel B ..........................................................6-7Spark plug .....................................................6-7

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TABLE OF CONTENTS

Final gear oil replacement ...........................6-9Air filter cleaning ..........................................6-9Carburetor adjustment ..............................6-11Throttle cable free play adjustment ..........6-11Tires .............................................................6-12Wheels ........................................................6-14Front brake adjustment .............................6-14Rear brake adjustment ...............................6-14Checking the front brake pads andbrake shoes .................................................6-15Inspecting the brake fluid level .................6-16Brake fluid replacement .............................6-16Cable inspection and lubrication ..............6-16Throttle cable and grip lubrication ...........6-17Autolube pump adjustment ......................6-17Brake lever lubrication ...............................6-17Center and sidestand lubrication ..............6-17Front fork inspection ..................................6-18Wheel bearings ..........................................6-18Steering inspection ....................................6-19Battery .........................................................6-19Fuse replacement .......................................6-20Headlight bulb replacement ......................6-21Turn signal and taillight bulbreplacement ................................................6-21License light bulb replacement .................6-22

Troubleshooting .........................................6-23Troubleshooting chart ...............................6-24

SCOOTER CARE AND STORAGE ....................7-1Care ...............................................................7-1Storage ..........................................................7-4

SPECIFICATIONS ..............................................8-1

CONSUMER INFORMATION ...........................9-1Identification numbers records ...................9-1Key identification number ...........................9-1Vehicle identification number .....................9-1Engine serial number ...................................9-2

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TABLE OF CONTENTS

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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 notignore the laws of physics.

Regular care and maintenance are essential for preserving your scooter’s value and operating condi-tion. Moreover, what is true for the scooter is also true for the rider: good performance depends onbeing in good shape. Riding under the influence of medication, drugs and alcohol is, of course, out ofthe question. Scooter riders - more than car drivers - must always be at their mental and physicalbest. Under the influence of even small amounts of alcohol, there is a tendency to take dangerousrisks.

Protective clothing is as essential for the scooter rider as seat belts are for car drivers and passen-gers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant syntheticmaterials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimumprotective wear, however, should not encourage carelessness. Though full-coverage helmets andsuits, in particular, create an illusion of total safety and protection, motorcyclists will always be vul-nerable. 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 anddefensively - avoiding all dangers, including those caused by others.

Enjoy your ride!

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Q GIVE SAFETY THE RIGHT OF WAY

1-1

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1-2

1. Left turn 1. Right turn

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FURTHER SAFE RIDING POINTS FOR THIS MODEL

8 Be sure to signal clearly whenmaking turns.

8 Braking can be extremely diffi-cult on a wet road. Avoid hardbraking, because the scootercould slide. Apply the brakesslowly when stopping on a wetsurface.

8 Slow down as you approach acorner or turn. Once you havecompleted a turn, accelerateslowly.

8 Be careful when passing parkedcars. A driver might not see youand open a door in your path.

8 Street car rails, iron plates onroad construction sites, andman-hole covers become ex-tremely slippery when wet.Slow down and cross them withcaution. Keep the scooter up-right. It could slide out from un-der you.

8 The brake lining could get wetwhen you wash the scooter. Af-ter washing the scooter, checkthe brakes before riding.

8 Always wear a helmet, gloves,trousers (tapered around thecuff and ankle so they do notflap), and a bright colored jacket.

8 Do not carry too much luggageon the scooter. An overloadedscooter is unstable.Use a strong cord to secure anyluggage to the luggage rack. Aloose load will affect the stabil-ity of the scooter and could di-vert your attention from theroad.

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DESCRIPTION

Left view

2-1

1. Headlights (page 6-20)2. Front turn signal (page 6-21)3. Luggage hook (page 3-8)4 Seat (page 3-6)5. Rear carrier (page 3-8)

6. Rear turn signal (page 6-21)7. Kick starter (page 3-6)8. Air filter (page 6-9)9. Centerstand (page 6-17)10. Sidestand (page 3-8)

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DESCRIPTION

Right view

2-2

11. Rear wheel (page 6-14)12. Rear turn signal (page 6-21)13. Taillight (page 6-21)14. Fuel tank (page 3-5)15. Trunk (page 3-7)

16. Battery (page 6-19)17. Front wheel (page 6-14)

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DESCRIPTION

Controls/Instruments

2-3

18. Rear brake lever (page 3-4)19. Left handlebar switches (page 3-3)20. Speedometer (page 3-2)21. Turn indicator (page 3-2)22. High beam indicator (page 3-2)

23. Oil level indicator light (page 3-2)24. Fuel gauge (page 3-2)25. Front brake lever (page 3-4)26. Right handlebar switches (page 3-3)

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Main switch/Steering lockThe main switch controls the igni-tion and lighting systems. Its opera-tion is described below.

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ONElectrical circuits are switched on.The engine can be started. The keycannot be removed in this position.

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OFFAll electrical circuits are switched off.The key can be removed in this po-sition.

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*The oil level indicator light shouldcome on. For details about the oillevel indicator light, refer to “Oillevel indicator light” on page 3-2.

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LOCKThe steering is locked in this posi-tion and all electrical circuits areswitched off.The key can be removed in this po-sition.To lock the steering, turn the handle-bars all the way to the left. With thekey at “OFF”, push it into the mainswitch and release it, turn it coun-terclockwise to “LOCK” and removeit. To unlock the steering, push thekey into the main switch and turn itto “OFF”.

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Never turn the key to “OFF” or“LOCK” when the scooter is mov-ing. The electrical circuits will beswitched off which may result inloss of control or an accident. Besure the motorcycle is stopped be-fore turning the key to “OFF” or“LOCK”.

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INSTRUMENT AND CONTROL FUNCTIONS

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Indicator lightsEAU00057

Turn indicator light “5”This indicator flashes when the turnswitch is moved to the left or right.

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High beam indicator light “&”This indicator comes on when theheadlight high beam is used.

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Oil level indicator light “7”The light comes on when the key isin the “*” position or when there islittle oil in the oil tank during opera-tion. If the oil indicator light comeson during operation, refill the tank

immediately with Yamalube 2 or 2-stroke engine oil (JASO FC grade orISO EG-C, EG-D grade). When thetank is refilled, the indicator lightshould go off.NOTE:If the oil indicator light does notcome on while the key is in the “*”position or does not go off when theoil level is sufficient, have a Yamahadealer inspect the oil indicator lightelectrical circuit.

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Do not run the scooter until youknow it has sufficient engine oil.

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SpeedometerThe speedometer shows ridingspeed.This speedometer is equipped withan odometer.

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Fuel gaugeThe fuel gauge indicates the quan-tity of the remaining gasoline in thetank. The gauge needle moves from“F” (Full) to “E” (Empty) as the fuellevel decreases. When the needlereaches the red line, refill the tank atthe earliest opportunity.


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1. Turn indicator light”5”2. High beam indicator light”&”3. Oil level indicator light”7”

1. Speedometer2. Fuel guage

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Handlebar switchesEAU00121

Dimmer switchTurn the switch to “&” for the highbeam and to “%” for the low beam.

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Turn signal switchTo signal a right-hand turn, push theswitch to “6”. To signal a left-handturn, push the switch to “4”. Oncethe switch is released it will returnto the center position.To cancel the signal, push the switchin after it has returned to the centerposition.

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

3-3

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Lights switchTurning the light switch to “'”,turns on the auxiliary light, meterlights and taillight. Turning the lightswitch to “:”, turns the headlighton also.

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Start switch “,“The starter motor cranks the enginewhen pushing the start switch.

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See starting instructions prior tostarting the engine.

1. Dimmer switch2. Turn signal switch3. Horn switch”*”

1. Light switch2. Start switch”,”

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3-4

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Front brake leverThe front brake lever is located onthe right handlebar. Pull it toward thehandlebar to apply the front brake.

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Rear brake leverThe rear brake lever is located on theleft handlebar. Pull it toward thehandlebar to apply the rear brake.

1. Fuel tank cap 2. Oil tank cap

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Fuel and oil tanksThe fuel tank and oil tank are locatedunder the seat.

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Be sure the caps are properly in-stalled before riding the scooter.

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3-5

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FuelMake sure there is sufficient fuel inthe tank. Fill the fuel tank to the bot-tom of the filler tube as shown in theillustration.

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Do not overfill the fuel tank. Avoidspilling fuel on the hot engine. Donot fill the fuel tank above the bot-tom of the filler tube or it may over-flow when the fuel heats up laterand expands.

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Always wipe off spilled fuel imme-diately with a dry and clean softcloth. Fuel may deteriorate paintedsurfaces or plastic parts.

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Recommended fuel:Regular unleaded gasolinewith a research octanenumber of 91 or higher.

Fuel tank capacity:Total:5.7 L

NOTE:

If knocking or pinging occurs, use adifferent brand of gasoline or higheroctane grade.

1. Filler tube 2. Fuel level

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1. Breather hose

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Fuel tank breather hoseThis model is equipped with a fueltank breather hose.Before using this motorcycle:9 Check the fuel tank breather

hose connection.

9 Check the fuel tank breatherhose for cracks or damage andreplace it if damaged.

9 Make sure the end of the fueltank breather hose is notblocked and clean it if necessary.

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3-6

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Kick starterRotate the kick starter away from theengine. Push the starter down lightlywith your foot until the gears en-gage, then kick smoothly and force-fully to start the engine.

1. Kick starter

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Two-stroke engine oilMake sure there is sufficient two-stroke engine oil in the oil tank. Addthe recommended oil as necessary.

Recommended oil:Yamalube 2 or 2-stroke engineoil (JASO FC grade or ISO EG-C, EG-D grade)

Oil tank capacity:1.4 L

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SeatTo openInsert the key into the main switchand turn it counterclockwise. Do notpush inward when turning the key.To closePush the seat downward to the origi-nal position and remove the keyfrom the main switch.NOTE:9 Place the scooter on the

centerstand before opening theseat.

9 Make sure the seat is securelyclosed before riding the scooter.

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3-7

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Helmet holderThe helmet holder is located underthe seat.Open the seat and hook the helmeton the helmet holder. Then lock theseat.

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Never ride with a helmet in the hel-met holder. The helmet may hit ob-jects, causing loss of control andpossibly an accident.

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TrunkThe trunk is under the seat.

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Do not exceed the load limit of 5 kg .

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Keep the following in mind whenusing the trunk.9 The trunk gets hot inside when

exposed to the sun. Do not putanything in the trunk suscep-tible to heat.

9 Put wet articles in a vinyl bagwhen storing them in the trunk.

9 The trunk may get wet whilethe scooter is being washed.Put articles in a vinyl bag beforestoring them in the trunk.

9 Do not put anything in the trunkthat is valuable or easy to break.

When storing a helmet in the trunk,place it upside-down with the frontfacing forward.

NOTE:Some helmets cannot be stored inthe trunk because of their size orshape.

Do not leave your scooter with theseat open.

1. Helmet holder 1. Trunk

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3-8

Front trunkEAUT0000

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Do not exceed the load limit of 1.5kg.

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SidestandThis model is equipped with an ig-nition circuit cut-off system. Thescooter must not be ridden when thesidestand is down. The sidestand islocated on the left side of the frame.(Refer to page 3-9 for an explanationof this system.)

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This scooter must not be operatedwith the sidestand in the down po-sition. If the stand is not properly re-tracted, it could contact the groundand distract the operator, resultingin a possible loss of control. Yamahahas designed into this scooter alockout system to assist the opera-tor in fulfilling the responsibility ofretracting the sidestand. Pleasecheck carefully the operating in-structions listed below and if thereis any indication of a malfunction,return the scooter to a Yamahadealer immediately for repair.

1. Front trunk 2. Luggage hook

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1. Rear carrier

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3-9

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Sidestand switch operationcheckCheck the operation of the sidestandswitch against the information be-low.

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Be sure to use the centerstand dur-ing this inspection.

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If improper operation is noted, con-sult a Yamaha dealer immediately.

Turn the main switch to “ON” .

Put the sidestand up.

Push the start switch while apply-ing either of the brake levers. Theengine will start.

Put the sidestand down.

If the engine stalls:

The sidestand switch is OK.

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4-1

Owners are personally responsible for their vehicle’s condition. Your scooter’s vital functions can start to deterio-rate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any dam-age, fluid leak or loss of tire pressure could have serious consequences. Therefore, it is very important that, inaddition to a thorough visual inspection, you check the following points before each ride.

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PRE-OPERATION CHECKS

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PRE-OPERATION CHECK LISTITEM CHECKS

9 Check operation, free play, fluid level and vehicle for fluid leakage.9 Fill with DOT 4 (or DOT 3) brake fluid if necessary.

9 Check operation, free play.

9Check for smooth operation.9 Lubricate.9Adjust throttle cable free play if necessary.

9Check oil level.9 Fill with oil if necessary.

9Check vehicle for leakage.

9Check tire pressure, wear, damage.

9Check for smooth operation.9 Lubricate if necessary.

9Make sure that all nuts, bolts, and screws are properly tightened.9 Tighten if necessary.

9Check fuel level.9 Fill with fuel if necessary.

9Check for proper operation.

Wheels and tires

Final gear oil

Engine oil

Throttle grip and housing

Rear brake

Front brake

Brake levers pivots

Lights, signals and switches

Fuel tank

Chassis fasteners

PAGE

3-4,6-14~6-16

3-4,6-14~6-15

6-11,6-17

3-6

6-9

6-12~6-14

6-17

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3-4~3-5

3-3

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4-2

PRE-OPERATION CHECKS

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

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If any item in the Pre-operation Check is not working properly, have it inspected and repaired before operating thescooter.

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OPERATION AND IMPORTANT RIDING POINTS

5-1

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9 Before riding this scooter, be-come thoroughly familiar withall operating controls and theirfunctions. Consult a Yamahadealer regarding any control orfunction that you do not thor-oughly understand.

9 Never start your engine or let itrun for any length of time in aclosed area. The exhaust fumesare poisonous and can causeloss of consciousness and deathwithin a short time. Always op-erate your scooter in an areawith adequate ventilation.

9 For safety, be sure to start theengine with the centerstanddown.

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Starting up a cold engine1. Turn the main switch to “*”. If

the oil level indicator lightcomes on, turn the main switchto “ON”.

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If the oil level indicator light doesnot come on, ask a Yamaha dealerto inspect it.

2. Completely close the throttlegrip.

3. Start the engine by pushing thestart switch while applying thefront or rear brake or by kickingthe kick starter.

NOTE:If the engine fails to start when us-ing the electric starter, release thestart switch, wait a few seconds, thentry again. Each attempt should be asshort as possible to preserve thebattery. Do not crank the enginemore than 5 seconds on any one at-

tempt. If the engine does not startwith the starter motor, kick the kickstarter to start the engine.

NOTE:For maximum engine life, alwayswarm up the engine about 1 ~ 3 min-utes before riding your scooter.Never accelerate hard with a coldengine.

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See the “Engine break-in” sectionprior to operating the motorcycle forthe first time.

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Starting offAfter warming up the engine:

1. Apply the rear brake lever withyour left hand and hold the grabbar with you right hand. Thenpush the scooter off thecenterstand.

2. Sit astride the seat and adjustthe rear view mirrors.

3. Check the oncoming traffic anduse a turn signal.

4. Turn the throttle grip on theright handlebar slowly and youwill start off. Remember to turnoff the turn signal.

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AccelerationThe speed can be adjusted by open-ing and closing the throttle grip.Turning it toward you increases thespeed, and turning it in the oppositedirection decreases the speed.

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

simultaneously with light pres-sure and increase the pressureslowly.

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9 Avoid hard or sudden braking.It may cause the scooter to skidor overturn.

9 Be sure to apply the brake care-fully if leaning over to one side.Improper braking could lead toa skid.

9 Street car rails, metal plates onroad construction sites, andman-hole covers become par-ticularly slippery when they getwet. Cross them slowly andcautiously.

9 Braking on a wet road is verydifficult.

9 Braking on a hill can be difficult.Proceed slowly when ridingdownhill.

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Engine break-inThere is never a more important pe-riod in the life of your scooter thanthe period between zero and 1,000km (600 mi). For this reason we askthat you carefully read the followingmaterial. Because the engine isbrand new, you must not put an ex-cessive load on it for the first 1,000km (600 mi). The various parts in theengine wear and polish themselvesto the correct operating clearances.During this period, prolonged fullthrottle operation, or any conditionwhich might result in excessiveheating of the engine, must beavoided.

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5-3

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0 ~ 150 km (0 ~ 100 mi)Avoid operation above 1/3 throttle.Stop the engine and let it cool for 5to 10 minutes after every hour ofoperation. Vary the speed of thescooter from time to time. Do not op-erate it at one set throttle position.150 ~ 500 km (100 ~ 300 mi)Avoid prolonged operation above1/2 throttle.500 ~ 1,000 km (300 ~ 600 mi)Avoid cruising speeds in excess of3/4 throttle.

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

1,000 km (600 mi) and beyondAvoid prolonged full throttle opera-tion. Vary speeds occasionally.

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If any engine trouble should occurduring the break-in period, consulta Yamaha dealer immediately.

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ParkingWhen parking the scooter, stop theengine and remove the ignition key.

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The exhaust system is hot. Park thescooter in a place where pedestri-ans or children are not likely totouch the scooter.Do not park the scooter on a slopeor soft ground the scooter may over-turn.

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6-1

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PERIODIC MAINTENANCE AND MINOR REPAIR

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Periodic inspection, adjustment andlubrication will keep your scooter inthe safest and most efficient condi-tion possible. Safety is an obligationof the scooter owner. The mainte-nance and lubrication schedule chartshould be considered strictly as aguide to general maintenance andlubrication intervals. YOU MUSTTAKE INTO CONSIDERATION THATWEATHER, TERRAIN, GEOGRAPHI-CAL LOCATIONS, AND A VARIETYOF INDIVIDUAL USES ALL TEND TODEMAND THAT EACH OWNER AL-TER THIS TIME SCHEDULE TOSHORTER INTERVALS TO MATCHTHE ENVIRONMENT. The most im-portant points of scooter inspection,adjustment, and lubrication are ex-plained in the following pages.

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If you are not familiar with scooterservice, this work should be done bya Yamaha dealer.

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This scooter is designed for use onpaved road surface only. If thisscooter is operated in abnormallydusty, muddy or wet conditions, theair filter should be cleaned or re-placed more frequently. Otherwise,rapid engine wear may result. Con-sult a Yamaha dealer for propermaintenance intervals.

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Tool kitThe service information included inthis manual is intended to provideyou, the owner, with the necessaryinformation for completing some ofyour own preventive maintenanceand minor repairs.The tools provided in the owner’stool kit are to assist you in the per-formance of periodic maintenance.However, some other tools such asa torque wrench are also necessaryto perform the maintenance cor-rectly.

1. Tool kit

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NOTE:

If you do not have necessary toolsrequired during a service operation,take your scooter to a Yamaha dealerfor service.

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Modifications to this scooter not ap-proved by Yamaha may cause lossof performance, and render it unsafefor use. Consult a Yamaha dealer be-fore attempting any changes.


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6-3


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Periodic maintenance and lubrication chart

CHECKS OR MAINTENANCE JOB

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*

*

*

*

*

*

*

*

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ITEMNo.ODOMETER READING(km)

1,000 6,000 12,000 18,000 24,000

ANNUAL

CHECK9Check fuel hoses and vacuum hose for cracks or damage.

9Replace.

9Clean.

9Replace.

9Check operation, fluid level and vehicle for fluid leakage.(See NOTE on page 6-5.)

9Replace brake pads.

9Check operation and adjust brake lever free play.

9Replace brake shoes.

9Check for cracks or damage.

9Replace. (See NOTE on page 6-5.)

9Check runout and for damage.

9Check tread depth and for damage.9Replace if necessary.9Check air pressure.9Correct if necessary.

9Check bearing for looseness or damage.

9Check bearing play and steering for roughness.

9 Lubricate with lithium-soap-based grease.

9Make sure that all nuts, bolts and screws are properly tight-ened.

9Check operation.9 Lubricate.

Fuel line

Spark plug

Air filter element

Front brake

Rear brake

Brake hose

Wheels

Tires

Wheel bearings

Steering bearings

Chassis fasteners

Sidestand/centerstand

√ √ √ √ √

√ √

√ √ √ √ √

√ √

√ √ √ √ √√

√ √ √ √ √√

√ √ √ √ √

√ √ √ √

√ √ √ √

√ √ √ √√ √ √ √√

√ √ √ √ √

√ √ √ √ √

Whenever worn to the limit

Whenever worn to the limit

Every 4 years

Every 24,000 km

4VP-F8199-E1.pm65 2/4/2004, 4:25 PM1

6-4


CHECKS OR MAINTENANCE JOBITEMNo.

13

14

15

16

17

18

19

20

21

22

*

*

*

*

*

*

*

*

Sidestand switch

Front fork

Rear shock absorberassembly

Carburetor

Autolube pump

Final gear oil

V-belt

Front and rear brakeswitches

Moving parts andcables

Lights, signals andswitches

9Check operation.

9Check operation and for oil leakage.

9Check operation and shock absorber for oil leakage.

9Check starter (choke) operation.9Adjust engine idling speed.

9Check operation.9Bleed if necessary.

9Check oil level and vehicle for oil leakage.

9Change.

9Replace.

9Check operation.

9 Lubricate.

9Check operation.9Adjust headlight beam.

ODOMETER READING(km)

1,000 6,000 12,000 18,000 24,000√ √ √ √ √√√ √ √ √

√ √ √ √

√ √ √√

√ √√

√ √√

√ √ √ √ √√

√ √ √ √ √

√ √ √ √ √√

ANNUAL

CHECK

Every 10,000 km

√ √ √ √ √√

4VP-F8199-E1.pm65 2/4/2004, 4:25 PM2


6-5

* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.

EAU01450

NOTE:8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.8 Hydraulic brake system9 When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the

brake fluid level regularly and fill as required.9 Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.9 Replace the brake hoses every four years or if cracked or damaged.

4VP-F8199-E1.pm65 2/4/2004, 4:25 PM3


EAU01139

Cowling and panel removaland installationThe cowlings and panels illustratedneed to be removed to performsome of the maintenance describedin this chapter.Refer to this section each time acowling or panel has to be removedor reinstalled.

1. Cowling 2. Panel

6-6

1. Protection bar 1. Cowling A

11

2

1

EAUT0483

Cowling ATo remove

1. Remove the front protection barby removing the bolts.

2. Remove the cowling screws,disconnect the headlight leadscoupler and remove the cowl-ing.

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM32


EAU01315

Panel BTo removeRemove the screws.

To installPlace the panel in the original posi-tion and install the screws.

6-7

1. Headlight leads coupler 1. Panel B

11

EAUT1529

Spark plugRemoval

1. Remove panel B. (Refer to page6-7 for removal and installationprocedures.)

2. Remove the spark plug cap.3. Use the spark plug wrench in the

tool kit to remove the spark plugas shown.

InspectionThe spark plug is an important en-gine component and is easy to in-spect. The condition of the sparkplug can indicate the condition of theengine.

1. Spark plug wrench

1

To install1. Connect the headlight leads

coupler.2. Place the cowling in the original

position and install the screws.3. Place the front protection bar in

the original position and installthe bolts.

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM33


6-8

The ideal color on the white insula-tor a round the center electrode is amedium-to-light tan color for ascooter that is being ridden nor-mally.

Do not attempt to diagnose suchproblems yourself. Instead, take thescooter to a Yamaha dealer . Youshould periodically remove and in-spect the spark plug because heatand deposits will cause any sparkplug to slowly break down anderode. If electrode erosion becomesexcessive, or if carbon and otherdeposits are excessive, you shouldreplace the spark plug.

Specified spark plug:BPR7HS (NGK)

Installation1. Measure the electrode gap with

a wire thickness gauge and, ifnecessary, adjust the gap tospecification.

Spark plug gap:0.9 ~ 1.0 mm

2. Clean the gasket surface. Wipeoff any grime from the threads.

3. Install the spark plug and tightenit to the specified torque, thenreplace the spark plug cap.

1. Spark plug gap

1

Tightening torque:Spark plug:

20 Nm (2.0 mkg)

NOTE:If a torque wrench is not availablewhen you are installing a sprarkplug, a good estimate of the correcttorque is 1/4 to 1/2 turn past fingertight. Have the spark plug tightenedto the specified torque as soon aspossible.

4. Install the panel.

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM34


6-9

1. Oil filler cap 1. Drain bolt 1. Carburetor joint clamp

1 1

1

EAU02961

Final gear oil replacement1. Put the scooter on the

centerstand.2. Place an oil pan under the final

gear case.3. Remove the oil filler cap and the

drain bolt to drain the oil.4. Install and tighten the drain bolt

to the specified torque.

Tightening torque:Drain bolt :

18 Nm (1.8 m.kg)

5. Fill the gear case with the rec-ommended oil.

Recommended final gear oil:SAE 85W140 type SE motor oilFinal gear oil quantity:

0.13 LEW000066

w

Do not let foreign material enter thefinal gear case. Be sure oil does notget on the tire or wheel.

6. Install the oil filler cap.

7. After replacing the final gear oil,be sure to check for oil leakage.

EAUT0624

Air filter cleaningThis air filter should be cleaned atthe specified intervals.It should be cleaned more frequentlyif you are riding in unusually wet ordusty areas.1. Remove panel B. (Refer to page

6-7 for removal and installationprocedures.)

2. Remove the carburetor jointclamp.

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM35


6-10

1

1. Air filter element1. Air filter case 2. Bolt 3.Screw

2

3

1

1. Air filter cover 2. Screw (×4)

2

1

3. Remove the air filter case bolt,loosen the air filter case jointscrew, and then remove the airfilter case.

4. Remove the air filter case coverby removing the screws, andthen remove the air filter ele-ment.

5. Wash the air filter element gen-tly, but thoroughly in solvent.

6. Squeeze out the excess solventand let the air filter element dry.

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM36


6-11

EAU00627

Carburetor adjustmentThe carburetor is a vital part of theengine and its emission control sys-tem. Adjusting should be left to aYamaha dealer with the professionalknowledge, specialized data andequipment to do so properly.

EAU00634

Throttle cable free playadjustmentNOTE:Before checking the throttle cablefree play, the engine idling speedshould be adjusted.

Adjust the throttle cable by turningthe adjusting nut so that specifiedfree play at the throttle grip is ob-tained.

Free play:3 ~ 5 mm

7. Apply oil to the entire surface ofthe air filter element andsqueeze out the excess oil. Itshould be damp, but not drip-ping.

Recommended oil:Engine oil

8. Coat the sealing edges of the airfilter case and air filter casecover lightly with grease for anairtight seal.

9. Install the air filter element andthe air filter case cover.

10.Install the air filter case and thecarburetor joint clamp.

11.Tighten the air filter case boltand the air filter case joint screw.

12.Install the panel.EC000082

cC

Make sure the air filter is properlyseated in the air filter case.The engine should never be runwithout the air filter installed. Exces-sive piston and/or cylinder wearmay result.

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM37


6-12

EAU00661

TiresTo ensure maximum performance,long service, and safe operation,note the following:Tire air pressureAlways check and adjust the tirepressure before operating thescooter.

EW000076

w

Tire inflation pressure should bechecked and adjusted when thetemperature of the tire equals theambient air temperature. Tire infla-tion pressure must be adjusted ac-cording to total weight of cargo,rider, and accessories (fairing,saddlebags, etc. if approved for thismodel), and vehicle speed.

CE-02E

Maximum load*: 160 kgCold tire pressure: Front Rear 200 kpa 200 kpaUp to 90 kg (2.00 kgf/cm2, (2.00 kgf/cm2, 2.00 bar) 2.00 bar) 90 kg load ~ 200 kpa 200 kpaMaximum load* (2.00 kgf/cm2, (2.00 kgf/cm2,

2.00 bar) 2.00 bar)

* Load is the total weight of cargo, rider and acces-sories.

1. Lock nut 2. Adjusting nut3. Free play

12

a

b

1. Loosen the locknut.2. Turn the adjusting nut in direc-

tion a to increase free play andin direction b to decrease freeplay.

3. Tighten the locknut.

EW000086

w

Proper loading of your scooter is im-portant for several characteristics ofyour scooter such as handling, brak-ing, performance and safety. Do notcarry loosely packed items that canshift. Securely pack your heaviestitems close to the center of thescooter, and distribute the weightevenly from side to side.Check the condition and pressure ofyour tires. NEVER OVERLOADYOUR SCOOTER. Make sure the to-tal weight of the cargo, rider, andaccessories (fairing, saddlebags, etc.if approved for this model) does notexceed the maximum load of thescooter. Operation of an overloadedscooter could cause tire damage, anaccident, or even injury.

3

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM38


6-13

Tire inspectionAlways check the tires before oper-ating the scooter. If center treaddepth reaches the limit as shown, ifthe tire has a nail or glass fragmentsin it, or if the side wall is cracked,contact a Yamaha dealer immedi-ately and have the tire replaced.

EW000084

w

For safe operation, when tires arereplaced, they must be replaced therecommended tire. Other rubbercompounds, tread patterns, tubetype tires or different ply rate tiresmay result in tire failure and/or

NOTE:

These limits may be different byregulation from country to country.If so, conform to the limits specifiedby the regulations of your own coun-try.

EAU00683

w

Operating the scooter with exces-sively worn tires decrease riding sta-bility and can lead to loss of control.Have excessively worn tiresreplaced by a Yamaha dealer imme-diately. Brakes, tires, and relatedwheel parts replacement should beleft to a Yamaha Service Technician.

CE-10E

FRONTManufacturer Size TypeCHENG-SHIN 120/90-10 56J

REARManufacturer Size TypeCHENG-SHIN 130/90-10 59J

CE-11E

Minimum tire treaddepth 1.6 mm(front and rear)

1

2

1. Tread depth 2. Side wall

scooter instability.

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM39


6-14

EAU00687

WheelsTo ensure maximum performance,long service, and safe operation,note the following:9 Always inspect the wheels be-

fore a ride. Check for cracks,bends, or warpage of thewheels. If any abnormal condi-tion exists in a wheel, consult aYamaha dealer.

9 Do not attempt even small re-pairs to the wheel. If a wheel isdeformed or cracked, it must bereplaced.

9 Tires and wheels should be bal-anced whenever either one ischanged or replaced. Failure tohave a wheel balanced can re-sult in poor performance, ad-verse handling characteristics,and shortened tire life.

9 Ride at moderate speeds afterchanging a tire since the tiresurface must first be broken infor it to develop its optimal char-acteristics.

EAU00697

Front brake adjustmentThe front brake lever should have afree play of 2 ~ 5 mm at the leverend. If not, ask a Yamaha dealer toadjust it.

EW000100

w

An incorrect free play indicates ahazardous condition in the brakesystem. Do not operate the motor-cycle until the failure in thebrake system is corrected. Ask aYamaha dealer for immediate re-pairs.

EAU00704

Rear brake adjustmentThe rear brake lever free play shouldbe adjusted to 10 ~ 20 mm at thebrake lever end. Adjustment is ac-complished at the brake hub.

a. Free play a. Free play

Front Rear

a a

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM40


6-15

EAU00720

Checking the front brake padsand rear brake shoes

EAU00723

Front brakeApply the brake and inspect the wearindicator.If the wear indicator is ALMOST incontact with the disc plate, ask aYamaha dealer to replace the pads.

EAU00727

Rear brakeApply the brake and inspect the wearindicator.If the indicator reaches the wear limitline, ask a Yamaha dealer to replacethe shoes.

1. Adjusting nut

1

1. Wear indicator2. Wear limit line

1

2

1. Wear indicator2. Brake disk3. Brake pads

1

2

3

To adjust, turn the adjusting nutclockwise to reduce play or counter-clockwise to increase play.

EW000101

w

When it is impossible to make theproper adjustment, ask a Yamahadealer.

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM41


6-16

ing leakage and poor brake per-formance.

Recommended brake fluid:DOT 4

NOTE:If DOT 4 is not available, DOT 3 canbe used.

9 Refill with the same type ofbrake fluid. Mixing fluids mayresult in a harmful chemical re-action and lead to poor brakeperformance.

9 Be careful that water does notenter the master cylinder whenrefilling. Water will significantlylower the boiling point of thefluid and may result in vaporlock.

9 Brake fluid may deterioratepainted surfaces or plastic parts.Always clean up spilled fluid im-mediately.

9 Have a Yamaha dealer check thecause if the brake fluid levelgoes down.

EAU00742

Brake fluid replacementThe brake fluid should be replacedonly by trained Yamaha service per-sonnel. Have the Yamaha dealer re-place the following components dur-ing periodic maintenance or whenthey are damaged or leaking:9 oil seals (every two years)9 brake hoses (every four years)

EAU00732

Inspecting the brake fluid levelInsufficient brake fluid may let airenter the brake system, possiblycausing the brakes to become inef-fective.Before riding, check that the brakefluid is above the minimum level andfill when necessary.Observe these precautions:9 When checking the fluid level,

make sure the top of the mastercylinder is level by turning thehandlebars.

9 Use only the designated qualitybrake fluid. Otherwise, the rub-ber seals may deteriorate, caus-

1. Minimum level line

1

EAU02962

Cable inspection and lubrica-tion

EW000112

w

Damage to the outer housing ofcables may lead to internal rustingand interfere with the cable move-ment. Replace damaged cables assoon as possible to prevent unsafeconditions.

Lubricate the cables and cable ends.If a cable does not operate smoothly,ask a Yamaha dealer to replace it.

Recommended lubricant:Engine oil

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM42


6-17

EAU00773

Throttle cable and grip lubri-cationThe throttle twist grip assemblyshould be greased at the time thatthe cable is lubricated, since the gripmust be removed to get at the endof the throttle cable. After removingthe screws, hold the end of the cableup in the air and put in several dropsof lubricant. With the throttle gripdisassembled, coat the metal surfaceof the grip assembly with a suitableall-purpose grease.

EAU00774

Autolube pump adjustmentThe autolube pump is a vital part ofthe engine and requires very sophis-ticated adjustment. Adjusting shouldbe left to a Yamaha dealer who hasthe professional knowledge and ex-perience to do so.

EAU00781

Brake lever lubricationLubricate the pivoting parts of bothbrake levers.


EAU02965

Center and sidestand lubrica-tionLubricate the pivoting and matingjoints.Check to see that the center andsidestand move up and downsmoothly.


EW000114

w

If the center and/or sidestand doesnot move smoothly, consult aYamaha dealer.

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM43


6-18

EAU01144

Wheel bearingsIf there is play in the front or rearwheel hub or if the wheel does notturn smoothly, have a Yamahadealer inspect the wheel bearings.

EAU02939

Front fork inspectionVisual check

EW000115

w

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

Check for scratches or damage onthe inner tube and excessive oil leak-age from the front fork. Operation check

1. Place the scooter on a levelplace.

2. Hold the scooter in an uprightposition and apply the frontbrake.

3. Push down hard on the handle-bars several times and check ifthe fork rebounds smoothly.

EC000098

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If any damage or unsmooth move-ment is found with the front fork,consult a Yamaha dealer.

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM44

EAU00794

Steering inspectionPeriodically inspect the condition ofthe steering. Worn out or loose steer-ing bearings may be dangerous.Place a stand under the engine toraise the front wheel off the ground.Hold the lower end of the front forksand try to move them forward andbackward. If any free play can be felt,ask a Yamaha dealer to inspect andadjust the steering. Inspection iseasier if the front wheel is removed.

EW000115

w

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


1. Battery

1

6-19

EAUT0800

BatteryThe battery is located under thefootboard. Remove panel B to accessthe battery. (Refer to page 6-7 forremoval and installation proce-dures.)This scooter is equipped with asealed battery. Therefore it is notnecessary to check the electrolyte orfill the battery with distilled water. Ifthe battery seems to have dis-charged, consult a Yamaha dealer.If the scooter is equipped with op-tional electrical accessories, the bat-tery tends to discharge more quickly,so be sure to recharge it periodically.

EC000101

cC

Never try to remove the sealing capsof the battery cells. The battery willbe damaged.

EW000116

w

Battery electrolyte is poisonous anddangerous, causing severe burns,etc. It contains sulfuric acid. Avoidcontact with skin, eyes or clothing.ANTIDOTE:EXTERNAL: Flush with water.INTERNAL: Drink large quantities ofwater or milk. Follow with milk ofmagnesia, beaten egg, or vegetableoil. Call a physician immediately.EYES: Flush with water for 15 min-utes and get prompt medical atten-tion.Batteries produce explosive gases.Keep sparks, flame, cigarettes etc.,away. Ventilate when charging orusing in an enclosed space. Alwaysshield your eyes when working near

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM45

1. Fuse

1


6-20

batteries.KEEP OUT OF REACH OF CHILDREN.

Battery storageWhen the scooter is not used for amonth or longer, remove the battery,fully charge it and store it in a cool,dry place.

EC000102

cC

Completely recharge the battery be-fore storing. Storing a dischargedbattery can cause permanent bat-tery damage.Use a battery charger designed fora sealed-type (MF) battery. Using aconventional battery charger willcause battery damage. If you do nothave a sealed-type battery charger,contact your Yamaha dealer.Always make sure the connectionsare correct when reinstalling thebattery.

EAUT0804

Fuse replacementThe fuse case is located beside thebattery. Remove panel B to accessthe battery. (Refer to page 6-7 forremoval and installation proce-dures.)

If the fuse is blown, turn off the mainswitch and all other switches. Installa new fuse of specified amperage.Turn on the switches and see if allelectrical devices operate. If the fuseimmediately blows again, consult aYamaha dealer.

EC000103

cC

Do not use fuses of higher amper-age rating than those recom-mended. Substitution of a fuse ofimproper rating can cause extensiveelectrical system damage and pos-sibly a fire.

Specified fuse:7A

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM46


6-21

EAUT1528

Headlight bulb replacementThis scooter is equipped with a S1bulb headlight. If the headlight bulbburns out, replace it as follows:

1. Remove cowling A. (See page6-6 for cowling removal and in-stallation procedures.)

2. Turn the bulb holder counter-clockwise to remove it and re-move the defective bulb.

1. Bulb holder

1

EW000119

w

Keep flammable products and yourhands away from a bulb while it ison, as it is hot. Do not touch a bulbuntil it cools down.

3. Put a new bulb into position andsecure it in place with the bulbholder.

EC000105

cC

Avoid touching the glass part of abulb. Keep it free from oil; other-wise, the transparency of the glass,life of the bulb, and luminous fluxwill be adversely affected. If oil getson a bulb, thoroughly clean it witha cloth moistened with alcohol orlacquer thinner.

4. Install the cowling.If the headlight beam adjustment isnecessary, ask a Yamaha dealer tomake that adjustment.

EAU00855

Turn signal and taillight bulbreplacement

1. Remove the screws and thelense.

2. Push the bulb inward and turnit counterclockwise.

1. Turn signal bulb

Front

1

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM47

EAUT1624

License light bulbreplacement

1. Remove the license light coverby removing the screws.

2. Push the bulb inward and turnit counterclockwise.

3. Place a new bulb in the socket.Push the bulb inward and turnit clockwise until it engages intothe socket.

4. Install the license light cover andthe screws.

1. Taillight bulb 1. Light cover 2. License light bulb

1 2

EC000108

cC

Do not over-tighten the screws asthe lense may break.

1


6-22

1. Turn signal bulb

Rear

1

3. Place a new bulb in the socket.Push the bulb inward and turnit clockwise until it engages intothe socket.

4. Install the lense and the screws.

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM48


6-23

EAU01008

TroubleshootingAlthough Yamaha scooters receivea rigid inspection before shipmentfrom the factory, trouble may occurduring operation.Any problem in the fuel, compres-sion, or ignition systems can causepoor starting and loss of power. Thetroubleshooting chart describes aquick, easy procedure for makingchecks.If your scooter requires any repair,bring it to a Yamaha dealer. Theskilled technicians at a Yamaha deal-ership have the tools, experience,and know-how to properly serviceyour motorcycle. Use only genuineYamaha parts on your scooter. Imi-tation parts may look like Yamahaparts, but they are often inferior.Consequently, they have a shorterservice life and can lead to expen-sive repair bills.

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM49


6-24

1. Fuel

2. Compression

3. Ignition

4. Battery

Check connectionsor recharge.

Check if there isfuel in the tank

Enough fuel Go to compression check.

No fuel Supply fuel.Engine doesn’t start, go tocompression check.

Use electric starter.

There is compression. Go to ignition check.

No compression. Ask a Yamaha dealer to inspect.

Remove sparkplug and checkelectrode.

Wet Wipe clean with dry cloth and correctspark gap or replace spark plugs.

Engine doesn’t start, go to batterycheck.

Dry Ask a Yamaha dealer to inspect.

Engine turns overquickly. Battery good.

Engine doesn’t start, ask a Yamahadealer to inspect.

Engine turns overslowly.

Use electricstarter

EAU01397

Troubleshooting chartEW000125

w

Never check the fuel system while smoking or in the vicinity of an open flame.

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM50

7-1

CareThe exposure of its technologymakes a scooter charming but alsovulnerable. Although high-qualitycomponents are used, they are notall rust-resistant. While a rusty ex-haust pipe may remain unnoticed ona car, it does look unattractive on ascooter. Frequent and proper care,however, will keep your scooterlooking good, extend its life andmaintain its performance. Moreover,the warranty states that the vehiclemust be properly taken care of. Forall these reasons, it is recommendedthat you observe the following clean-ing and storing precautions.

EAU01522

SCOOTER CARE AND STORAGE

Before cleaning1. Cover up the muffler outlet with

a plastic bag.2. Make sure that all caps and cov-

ers as well as all electrical cou-plers and connectors, includingthe spark plug cap, are tightlyinstalled.

3. Remove extremely stubborndirt, like oil burnt onto the crank-case, with a degreasing agentand a brush, but never applysuch products onto seals, gas-kets and wheel axles. Alwaysrinse the dirt and degreaser offwith water.

CleaningAfter normal useRemove dirt with warm water, a neu-tral detergent and a soft cleansponge, then rinse with plenty ofclean water. Use a tooth and bottlebrush for hard-to-reach parts.Tougher dirt and insects will comeoff more easily if the area is coveredwith a wet cloth for a few minutesbefore cleaning.

ECA00011

cC

9 Avoid using strong acidic wheelcleaners. If you do use suchproducts for hard-to-removedirt, do not leave it on anylonger than instructed, thenthoroughly rinse it off with wa-ter, immediately dry the areaand apply a corrosion protec-tion spray.

4VP-F8199-E1.pm65 2/4/2004, 4:21 PM51

9 Improper cleaning can damagewindshields, cowlings, panelsand other plastic parts. Use onlya soft, clean cloth or spongewith mild detergent and waterto clean plastic.

9 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), rust re-movers or inhibitors, brakefluid, antifreeze or electrolyte.

9 Do not use high-pressure wash-ers or steam-jet cleaners sincethey cause water seepage anddeterioration in the followingareas: seals (of wheel bearings,swingarm bearings, bearings,forks and brakes), electric com-ponents (couplers, connectors,instruments, switches andlights), breather hoses andvents.

9 For scooters equipped with awindshield: Do not use strongcleaners or hard sponges asthey will cause dulling orscratching. Some cleaning com-pounds for plastic may leavescratches on the windshield.Test the product on a small hid-den part of the windshield tomake sure they do not leave anymarks. If the windshield isscratched, use a quality plasticpolishing compound afterwashing.

After riding in the rain, near the seaor on salt-sprayed roadsSince sea salt or salt sprayed on theroads in the winter are extremelycorrosive in combination with water,carry out the following steps aftereach ride in the rain, near the sea oron salt-sprayed roads. (Salt sprayedin the winter may remain on theroads well into spring.)

1. Clean your scooter with cold wa-ter and soap after the engine hascooled down.

ECA00012

cC

Do not use warm water since it in-creases the corrosive action of thesalt.

2. Be sure to apply a corrosion pro-tection spray on all (evenchrome- and nickel-plated)metal surfaces to prevent corro-sion.


7-2

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7-3

After cleaning1. Dry the scooter with a chamois

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

chrome, aluminum and stain-less-steel parts, including theexhaust system. (Even the ther-mally induced discoloring ofstainless-steel exhaust systemscan be removed through polish-ing.)

3. To prevent corrosion, it is rec-ommended to apply a corrosionprotection spray on all (evenchrome- and nickel-plated)metal surfaces.

4. Use spray oil as a universalcleaner to remove any remain-ing dirt.

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

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

before storing it or covering it.

EWA00002

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Make sure that there is no oil or waxon the brakes and tires. If necessary,clean the brake discs and liningswith a regular brake disc cleaner oracetone, and wash the tires withwarm water and mild soap. Then,carefully test the scooter for its brak-ing performance and cornering be-havior.

ECA00013

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9 Apply spray oil and wax spar-ingly and wipe off any excess.

9 Never apply oil or wax on rub-ber and plastic parts, but treatthem with a suitable care prod-uct.

9 Avoid using abrasive polishingcompounds as they wear awaythe paint.

NOTE:

Consult a Yamaha dealer for adviceon what products to use.

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StorageShort-termAlways store your scooter in a cool,dry place and, if necessary, protectit against dust with a porous cover.

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9 Storing the scooter in a poorlyventilated room or covering itwith a tarp while it is still wetwill allow water and humidityto seep in and cause rust.

9 To prevent corrosion, avoiddamp cellars, stables (becauseof the presence of ammonia)and areas where strong chemi-cals are stored.

7-4

Long-termBefore storing your scooter for sev-eral months:

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

2. Drain the carburetor float cham-bers by loosening the drainbolts; this will prevent fuel de-posits from building up. Pourthe drained fuel into the fueltank.

3. Only for scooters equipped witha fuel cock which has an “OFF”position: Turn the fuel cock to“OFF”.

4. Fill up the fuel tank and add fuelstabilizer (if available) to preventthe fuel tank from rusting andthe fuel from deteriorating.

5. Perform the following steps toprotect the cylinder, pistonrings, etc. from corrosion.

a. Remove the spark plug cap andspark plug.

b. Pour a teaspoonful of engineoil into the spark plug bore.

c. Install the spark plug cap ontothe spark plug and place thespark plug on the cylinder headso that the electrodes aregrounded. (This will limit spark-ing 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, install thespark plug and then the sparkplug cap.

EWA00003

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When turning the engine over, besure to ground the spark plug elec-trodes to prevent damage or injuryfrom sparking.

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7-5

6. Lubricate all control cables andthe pivoting points of all leversand pedals as well as of thesidestand/centerstand.

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

8. Cover up the muffler outlet witha plastic bag to prevent mois-ture from entering.

9. Remove the battery and fullycharge it. Store it in a cool, dryplace and recharge it once amonth. Do not store the batteryin an excessively cold or warmplace (less than 0°C or morethan 30°C). For more informa-tion, see “Battery storage” in thechapter “PERIODIC MAINTE-NANCE AND MINOR REPAIRS”.

NOTE:

Make any necessary repairs beforestoring the scooter.

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EAU01038

SPECIFICATIONS

8-1

Model YW 100E

Dimensions

Overall length 1,890 mm

Overall width 660 mm

Overall height 1,115 mm

Seat height 765 mm

Wheel base 1,270 mm

Ground clearance 119 mm

Minimum turning radius 1,800 mmBasic weight with oil and full

fuel tank 96 kg

Engine

Engine type Air-cooled 2-stroke

Cylinder arrangement Forward-inclined single cylinder

Displacement 101 cm3

Bore × Stroke 52.0 × 47.6 mm

Compression ratio 6.6:1

Starting system Electric / kick starter

Lubrication system Separate lubrication

Specifications

Engine oilType Yamalube 2 or 2-stroke

engine oil (JASO FC grade

or ISO EG-C, EG-D grade)

Total amount 1.4 L

Final gear oil

Type SAE 85 W 140

Total amount 0.13 L

Air filter Wet type element

Fuel

Type Regular unleaded gasoline

Fuel tank capacity 5.7 L

Carburetor

Type × quantity VM16SS × 1

Manufacturer Taiwan Mikuni

Spark plug

Type / Manufacturer BPR7HS / NGK

Spark plug gap 0.9 ~ 1.0 mm

Clutch type Dry, centrifugal automatic

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Transmission

Primary reduction system Helical gear

Primary reduction ratio 3.133

Secondary reduction system Spur gear

Secondary reduction ratio 3.308

Transmission type V-belt automatic

Operation Centrifugal automatic type

Chassis

Frame type Steel tube underbone

Caster angle 26°

Trail 86 mm

Tire Tubeless

Front

Size 120/90-10

Manufacuturer/model CHENG SHIN/56J

Rear

SIZE 130/90-10

Manufacuturer/model CHENG SHIN/59J

Manufacturer/model

Front CHENG SHIN / 56J

Rear CHENG SHIN / 59J

Maximum load* 160 kg

Air pressure

Up to 90 kg load*

Front 200 kpa(2.0 kg / cm2,2.0 bar)

Rear 200 kpa(2.0 kg / cm2,2.0 bar)

90 kg load ~ maximum load*

Front 200 kpa(2.0 kg / cm2,2.0 bar)

Rear 200 kpa(2.0 kg / cm2,2.0 bar)

*Load is total weight of cargo, rider and accessories.

SPECIFICATIONS

8-2

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Wheels

Type

Front Cast wheel

Rear Cast wheel

Size

Front MT 3.5 × 10

Rear MT 3.5 × 10

Brakes

Front

Type Single disc brake

Operation Right hand operation

Fluid DOT 3 or DOT 4

Rear

Type Drum brake

Operation Left hand operation

Suspension

Front Telescopic fork

Inner tube outer

diameter 30 mm

Rear Unit swing

Shock absorber

Front Coil spring / oil damper

Rear Coil spring / oil damper

Wheel travel

Front 70 mm

Rear 55 mm

Electrical

Ignition system C.D.I.

Charging system

Type A.C. magneto

Standard output 13~14 V / 4,000rpm

Battery

Type YTX 5 L-BS

Voltage, capacity 12 V, 4 AH

Headlight type S1 bulb

Bulb voltage, wattage × quantity

Headlight 12 V, 25 / 25 W × 2

Tail / brake light 12 V, 5 / 21 W × 1

Turn signal light 12 V, 10 W × 4

SPECIFICATIONS

8-3

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SPECIFICATIONS

Auxiliary light 12 V 5 W × 2

License light 12 V 5 W × 1

Meter light 12 V 1.7 W × 1 + 3.4 W × 1

High beam indicator light 12 V 1.7 W × 1

Turn indicator light 12 V 1.7 W × 1

Oil level indicator light 12 V 1.7 W × 1

Fuse 7A

8-4

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EAU01039

CONSUMER INFORMATION

EAU01042

Key identification numberThe key identification number isstamped on the key.Record this number in the space pro-vided and use it for reference whenobtaining a new key.

9-1

1. Key identification number

1

1

1. Vehicle identification number

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Vehicle identification numberThe vehicle identification number isstamped into the frame.NOTE:The vehicle identification number isused to identify your motorcycle andmay be used to register your motor-cycle with the licensing authority inyour state.

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Identification number recordsRecord the key identification num-ber, vehicle identification numberand engine serial number in thespaces provided for assistance whenordering spare parts from a Yamahadealer or for reference in case thevehicle is stolen.

1. KEY IDENTIFICATION NUMBER:

2. VEHICLE IDENTIFICATIONNUMBER:

3. ENGINE SERIAL NUMBER:

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CONSUMER INFORMATION

9-2

EAU01047

Engine serial numberThe engine serial number is stampedinto the crankcase.

1. Engine serial number

1

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PRINTED IN TAIWAN2000.11-1 * 1(E) !

YAMAHA MOTOR TAIWAN CO.,LTD

Manual Moto

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