User manual YAMAHA 20EH SERVICE MANUAL

[. . . ] 2007 General manager of quality assurance div. INTRODUCTION EAU10112 Welcome to the Yamaha world of motorcycling!As the owner of the XP500/XP500A, you are benefiting from Yamaha's vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XP500/XP500A. The Owner's Manual does not only instruct you in how to operate, inspect and maintain your scooter, but also in how to safeguard yourself and others from trouble and injury. [. . . ] The scooter should not be ridden until checked by a Yamaha dealer. NO YES 3 4 5 With the engine still off: 6. Does the engine stall? NO The brake switch may not be working correctly. The scooter should not be ridden until checked by a Yamaha dealer. 6 7 YES NO The sidestand switch may not be working correctly. The scooter should not be ridden until checked by a Yamaha dealer. 8 9 The system is OK. The scooter can be ridden. 3-24 FOR YOUR SAFETY ­ PRE-OPERATION CHECKS EAU15596 Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual. 1 2 3 4 Fuel EWA11151 WARNING Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points: ITEM G G G G CHECKS Check fuel level in fuel tank. Check hydraulic system for leakage. PAGE 3-16 5 Engine oil G G 6-11 6-14 6-15 6 Chain drive oil G G 7 8 9 Coolant G G G G G Front brake G G G G 6-21, 6-22, 6-23 4-1 FOR YOUR SAFETY ­ PRE-OPERATION CHECKS ITEM G G G CHECKS Check operation. If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. 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. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided. EAU36531 1600 km (1000 mi) and beyond The vehicle can now be operated normally. ECA10310 EAU17213 Parking When parking, stop the engine, and then remove the key from the main switch. EWA10311 NOTICE G Keep the engine speed out of the tachometer red zone. G If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle. G G G WARNING Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them and be burned. Do not park on a slope or on soft ground, otherwise the vehicle may overturn, increasing the risk of a fuel leak and fire. Do not park near grass or other flammable materials which might catch fire. 2 3 4 5 6 7 8 9 0­1000 km (0­600 mi) Avoid prolonged operation above 4000 r/min. NOTICE: After 1000 km (600 mi) of operation, the engine oil must be changed, and the oil filter cartridge or element replaced. [ECA11282] 1000­1600 km (600­1000 mi) Avoid prolonged operation above 6000 r/min. 5-4 PERIODIC MAINTENANCE AND ADJUSTMENT EAU17281 EWA15121 maintenance intervals. 1 2 3 4 5 6 7 8 9 Periodic inspection, adjustment, and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of vehicle inspection, adjustment, and lubrication are explained on the following pages. The intervals given in the periodic maintenance and lubrication chart should be simply considered as a general guide under normal riding conditions. However, depending on the weather, terrain, geographical location, and individual use, the maintenance intervals may need to be shortened. EWA10321 WARNING Turn off the engine when performing maintenance unless otherwise specified. G A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires. [. . . ] Follow all the instructions in the "Care" section of this chapter. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the NOTICE G Apply spray oil and wax sparingly and make sure to wipe off any excess. G Never apply oil or wax to any rubber and plastic parts, but 7-3 SCOOTER CARE AND STORAGE fuel from deteriorating. Perform the following steps to protect the cylinders, piston rings, etc. [. . . ]