Instrukcja obsługi Yamaha BW100 (2005)

Yamaha skuter BW100 (2005)

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4VP-F8199-E1
YW100E
OWNER’S MANUAL
EAU00001
Welcome to the Yamaha world of motorcycling!
As the owner of a BW’S100, you are benefiting from Yamaha’s vast experience in and newest
technology for the design and the 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 your BW’S100’s advan-
tages. 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.
In addition, the many tips given in this manual will help to keep your scooter in the best possible
condition. 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
EAU00005
Particularly important information is distinguished in this manual by the following notations:
IMPORTANT MANUAL INFORMATION
NOTE:
9This manual should be considered a permanent part of this scooter and should remain with it
even if the scooter is subsequently sold.
9Yamaha continually seeks advancements in product design and quality. Therefore, while this
manual contains the most current product information available at the time of printing, there
may be minor discrepancies between your scooter and this manual. If there is any question
concerning this manual, please consult your Yamaha dealer.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
A NOTE provides key information to make procedures easier or clearer.
A CAUTION indicates special precautions that must be taken to avoid damage to
the scooter.
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.
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NOTE:
Q
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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS SCOOTER.
IMPORTANT MANUAL INFORMATION
EAU00008
YW100E
OWNER’S MANUAL
© 1999 by Yamaha Motor Taiwan Co., Ltd.
1st Edition, March 1999
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Taiwan Co., Ltd.
is expressly prohibited.
Printed in Taiwan
EAU00009
TABLE OF CONTENTS
GIVE SAFETY THE RIGHT OF WAY ................. 1-1
FURTHER SAFE RIDING POINTS FOR THIS
MODEL ..............................................................1-2
DESCRIPTION ................................................... 2-1
Left view ........................................................ 2-1
Right view .....................................................2-2
Controls / Instruments .................................2-3
INSTRUMENT AND CONTROL
FUNCTIONS ......................................................3-1
Main switch / Steering lock .........................3-1
Indicator lights .............................................. 3-2
Speedometer ................................................3-2
Fuel gauge ....................................................3-2
Handlebar switches ......................................3-3
Front brake lever ..........................................3-4
Rear brake lever ...........................................3-4
Fuel and oil tanks .........................................3-4
Fuel ................................................................3-5
Fuel tank breather hose ...............................3-5
Two-storoke engine oil ................................3-6
Kick starter .................................................... 3-6
Seat ...............................................................3-6
Helmet holder ...............................................3-7
Trunk .............................................................3-7
Rear carrier ...................................................3-8
Front trunk ....................................................3-8
Luggage hook ...............................................3-8
Sidestand ......................................................3-8
Sidestand switch operation check ..............3-9
PRE-OPERATION CHECKS ...............................4-1
Pre-operation check list ...............................4-1
OPERATION AND IMPORTANT RIDING
POINTS .............................................................. 5-1
Starting up a cold engine ............................5-1
Starting off ....................................................5-2
Acceleration ..................................................5-2
Braking ..........................................................5-2
Engine break-in ............................................5-2
Parking ..........................................................5-3
PERIODIC MAINTENANCE AND MINOR
REPAIR ..............................................................6-1
Took kit.......................................................... 6-1
Periodic maintenance and lubrication ........6-3
Cowling and panel removal and
installation ....................................................6-6
Cowling A .....................................................6-6
Panel B ..........................................................6-7
Spark plug ..................................................... 6-7
1
2
3
4
5
6
TABLE OF CONTENTS
Final gear oil replacement ........................... 6-9
Air filter cleaning ..........................................6-9
Carburetor adjustment ..............................6-11
Throttle cable free play adjustment ..........6-11
Tires .............................................................6-12
Wheels ........................................................6-14
Front brake adjustment .............................6-14
Rear brake adjustment ...............................6-14
Checking the front brake pads and
brake shoes ................................................. 6-15
Inspecting the brake fluid level ................. 6-16
Brake fluid replacement .............................6-16
Cable inspection and lubrication .............. 6-16
Throttle cable and grip lubrication ...........6-17
Autolube pump adjustment ......................6-17
Brake lever lubrication ...............................6-17
Center and sidestand lubrication ..............6-17
Front fork inspection ..................................6-18
Wheel bearings ..........................................6-18
Steering inspection ....................................6-19
Battery .........................................................6-19
Fuse replacement .......................................6-20
Headlight bulb replacement ...................... 6-21
Turn signal and taillight bulb
replacement ................................................6-21
License light bulb replacement ................. 6-22
Troubleshooting .........................................6-23
Troubleshooting chart ...............................6-24
SCOOTER CARE AND STORAGE ....................7-1
Care ...............................................................7-1
Storage ..........................................................7-4
SPECIFICATIONS ..............................................8-1
CONSUMER INFORMATION ...........................9-1
Identification numbers records ...................9-1
Key identification number ...........................9-1
Vehicle identification number .....................9-1
Engine serial number ................................... 9-2
7
8
9
TABLE OF CONTENTS
Scooters are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom.
However, they also impose certain limits, which you must accept; even the best scooter does not
ignore the laws 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 on
being in good shape. Riding under the influence of medication, drugs and alcohol is, of course, out of
the question. Scooter riders - more than car drivers - must always be at their mental and physical
best. Under the influence of even small amounts of alcohol, there is a tendency to take dangerous
risks.
Protective clothing is as essential for the scooter rider as seat belts are for car drivers and passen-
gers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic
materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum
protective wear, however, should not encourage carelessness. Though full-coverage helmets and
suits, 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 and
defensively - avoiding all dangers, including those caused by others.
Enjoy your ride!
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Q GIVE SAFETY THE RIGHT OF WAY
1-1
1-2
1. Left turn 1. Right turn
EAU02964
FURTHER SAFE RIDING POINTS FOR THIS MODEL
8Be sure to signal clearly when
making turns.
8Braking can be extremely diffi-
cult on a wet road. Avoid hard
braking, because the scooter
could slide. Apply the brakes
slowly when stopping on a wet
surface.
8Slow down as you approach a
corner or turn. Once you have
completed a turn, accelerate
slowly.
8Be careful when passing parked
cars. A driver might not see you
and open a door in your path.
8Street car rails, iron plates on
road construction sites, and
man-hole covers become ex-
tremely slippery when wet.
Slow down and cross them with
caution. Keep the scooter up-
right. It could slide out from un-
der you.
8The brake lining could get wet
when you wash the scooter. Af-
ter washing the scooter, check
the brakes before riding.
8Always wear a helmet, gloves,
trousers (tapered around the
cuff and ankle so they do not
flap), and a bright colored jacket.
8Do not carry too much luggage
on the scooter. An overloaded
scooter is unstable.
Use a strong cord to secure any
luggage to the luggage rack. A
loose load will affect the stabil-
ity of the scooter and could di-
vert your attention from the
road.
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)
5
6
9
4
3
2
1
7
8
0
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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20
40
60 80
100
120
140
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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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s
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o
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Main switch/Steering lock
The main switch controls the igni-
tion and lighting systems. Its opera-
tion is described below.
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ON
Electrical circuits are switched on.
The engine can be started. The key
cannot be removed in this position.
EAU00038
OFF
All electrical circuits are switched off.
The key can be removed in this po-
sition.
EAU02954
*
The oil level indicator light should
come on. For details about the oil
level indicator light, refer to “Oil
level indicator light” on page 3-2.
EAUT0042
LOCK
The steering is locked in this posi-
tion and all electrical circuits are
switched 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 the
key at “OFF”, push it into the main
switch and release it, turn it coun-
terclockwise to “LOCK” and remove
it. To unlock the steering, push the
key into the main switch and turn it
to “OFF”.
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Never turn the key to “OFF” or
“LOCK” when the scooter is mov-
ing. The electrical circuits will be
switched off which may result in
loss of control or an accident. Be
sure the motorcycle is stopped be-
fore turning the key to “OFF” or
“LOCK”.
3-1
INSTRUMENT AND CONTROL FUNCTIONS
0
20
40
60 80
100
120
140
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Indicator lights
EAU00057
Turn indicator light “5”
This indicator flashes when the turn
switch is moved to the left or right.
EAU00063
High beam indicator light “&”
This indicator comes on when the
headlight high beam is used.
EAU02958
Oil level indicator light “7”
The light comes on when the key is
in the “*” position or when there is
little oil in the oil tank during opera-
tion. If the oil indicator light comes
on during operation, refill the tank
immediately with Yamalube 2 or 2-
stroke engine oil (JASO FC grade or
ISO EG-C, EG-D grade). When the
tank is refilled, the indicator light
should go off.
NOTE:
If the oil indicator light does not
come on while the key is in the “*”
position or does not go off when the
oil level is sufficient, have a Yamaha
dealer inspect the oil indicator light
electrical circuit.
EC000000
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Do not run the scooter until you
know it has sufficient engine oil.
EAU00098
Speedometer
The speedometer shows riding
speed.
This speedometer is equipped with
an odometer.
EAU02950
Fuel gauge
The fuel gauge indicates the quan-
tity of the remaining gasoline in the
tank. The gauge needle moves from
“F” (Full) to “E” (Empty) as the fuel
level decreases. When the needle
reaches the red line, refill the tank at
the earliest opportunity.
INSTRUMENT AND CONTROL FUNCTIONS
3-2
1. Turn indicator light”5”
2. High beam indicator light”&”
3. Oil level indicator light”7”
1. Speedometer
2. Fuel guage
1 2 3
0
20
40
60 80
100
120
140
0000001
1 2
INSTRUMENT AND CONTROL FUNCTIONS
EAU00118
Handlebar switches
EAU00121
Dimmer switch
Turn the switch to “ ” for the high&
beam and to “ ” for the low beam.%
EAU00127
Turn signal switch
To signal a right-hand turn, push the
switch to “ ”. To signal a left-hand6
turn, push the switch to “ ”. Once4
the switch is released it will return
to the center position.
To cancel the signal, push the switch
in after it has returned to the center
position.
EAU00129
Horn switch “*”
Press the switch to sound the horn.
3-3
EAU00134
Lights switch
Turning the light switch to “'”,
turns on the auxiliary light, meter
lights and taillight. Turning the light
switch to “ ”, turns the headlight:
on also.
EAU00143
Start switch “,“
The starter motor cranks the engine
when pushing the start switch.
EC000005
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See starting instructions prior to
starting the engine.
1. Dimmer switch
2. Turn signal switch
3. Horn switch”*”
1. Light switch
2. Start switch”,”
123 1 2
INSTRUMENT AND CONTROL FUNCTIONS
3-4
EAU00158
Front brake lever
The front brake lever is located on
the right handlebar. Pull it toward the
handlebar to apply the front brake.
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Rear brake lever
The rear brake lever is located on the
left handlebar. Pull it toward the
handlebar to apply the rear brake.
1. Fuel tank cap 2. Oil tank cap
2
1
EAU02966
Fuel and oil tanks
The fuel tank and oil tank are located
under the seat.
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Be sure the caps are properly in-
stalled before riding the scooter.
INSTRUMENT AND CONTROL FUNCTIONS
3-5
EAU01183
Fuel
Make sure there is sufficient fuel in
the tank. Fill the fuel tank to the bot-
tom of the filler tube as shown in the
illustration.
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Do not overfill the fuel tank. Avoid
spilling fuel on the hot engine. Do
not fill the fuel tank above the bot-
tom of the filler tube or it may over-
flow when the fuel heats up later
and expands.
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Always wipe off spilled fuel imme-
diately with a dry and clean soft
cloth. Fuel may deteriorate painted
surfaces or plastic parts.
EAU00191
Recommended fuel:
Regular unleaded gasoline
with a research octane
number of 91 or higher.
Fuel tank capacity:
Total:
5.7 L
NOTE:
If knocking or pinging occurs, use a
different brand of gasoline or higher
octane grade.
1. Filler tube 2. Fuel level
12
1. Breather hose
1
EAU02955
Fuel tank breather hose
This model is equipped with a fuel
tank breather hose.
Before using this motorcycle:
9 Check the fuel tank breather
hose connection.
9 Check the fuel tank breather
hose for cracks or damage and
replace it if damaged.
9 Make sure the end of the fuel
tank breather hose is not
blocked and clean it if necessary.
INSTRUMENT AND CONTROL FUNCTIONS
3-6
EAU00214
Kick starter
Rotate the kick starter away from the
engine. Push the starter down lightly
with your foot until the gears en-
gage, then kick smoothly and force-
fully to start the engine.
1. Kick starter
1
EAU02956
Two-stroke engine oil
Make sure there is sufficient two-
stroke engine oil in the oil tank. Add
the recommended oil as necessary.
Recommended oil:
Yamalube 2 or 2-stroke engine
oil (JASO FC grade or ISO EG-
C, EG-D grade)
Oil tank capacity:
1.4 L
EAU02959
Seat
To open
Insert the key into the main switch
and turn it counterclockwise. Do not
push inward when turning the key.
To close
Push the seat downward to the origi-
nal position and remove the key
from the main switch.
NOTE:
9Place the scooter on the
centerstand before opening the
seat.
9Make sure the seat is securely
closed before riding the scooter.
INSTRUMENT AND CONTROL FUNCTIONS
3-7
EAU00262
Helmet holder
The helmet holder is located under
the seat.
Open the seat and hook the helmet
on the helmet holder. Then lock the
seat.
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Never ride with a helmet in the hel-
met holder. The helmet may hit ob-
jects, causing loss of control and
possibly an accident.
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Trunk
The trunk is under the seat.
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Do not exceed the load limit of 5 kg .
EC000010
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Keep the following in mind when
using the trunk.
9The trunk gets hot inside when
exposed to the sun. Do not put
anything in the trunk suscep-
tible to heat.
9Put wet articles in a vinyl bag
when storing them in the trunk.
9The trunk may get wet while
the scooter is being washed.
Put articles in a vinyl bag before
storing them in the trunk.
9Do not put anything in the trunk
that is valuable or easy to break.
When storing a helmet in the trunk,
place it upside-down with the front
facing forward.
NOTE:
Some helmets cannot be stored in
the trunk because of their size or
shape.
Do not leave your scooter with the
seat open.
1. Helmet holder 1. Trunk
1
1
INSTRUMENT AND CONTROL FUNCTIONS
3-9
EAUT0337
Sidestand switch operation
check
Check the operation of the sidestand
switch 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. The
engine will start.
Put the sidestand down.
If the engine stalls:
The sidestand switch is OK.
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, in
addition to a thorough visual inspection, you check the following points before each ride.
EAU01114
PRE-OPERATION CHECKS
EAU00340
PRE-OPERATION CHECK LIST
ITEM CHECKS
9Check operation, free play, fluid level and vehicle for fluid leakage.
9Fill with DOT 4 (or DOT 3) brake fluid if necessary.
9Check operation, free play.
9Check for smooth operation.
9Lubricate.
9Adjust throttle cable free play if necessary.
9Check oil level.
9Fill with oil if necessary.
9Check vehicle for leakage.
9Check tire pressure, wear, damage.
9Check for smooth operation.
9Lubricate if necessary.
9Make sure that all nuts, bolts, and screws are properly tightened.
9Tighten if necessary.
9Check fuel level.
9Fill 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
_
3-4~3-5
3-3
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 a
very 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 the
scooter.
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OPERATION AND IMPORTANT RIDING POINTS
5-1
EAU01118
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9Before riding this scooter, be-
come thoroughly familiar with
all operating controls and their
functions. Consult a Yamaha
dealer regarding any control or
function that you do not thor-
oughly understand.
9Never start your engine or let it
run for any length of time in a
closed area. The exhaust fumes
are poisonous and can cause
loss of consciousness and death
within a short time. Always op-
erate your scooter in an area
with adequate ventilation.
9For safety, be sure to start the
engine with the centerstand
down.
EAU02960
Starting up a cold engine
1. Turn the main switch to “*”. If
the oil level indicator light
comes on, turn the main switch
to “ON”.
EC000045
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If the oil level indicator light does
not come on, ask a Yamaha dealer
to inspect it.
2. Completely close the throttle
grip.
3. Start the engine by pushing the
start switch while applying the
front or rear brake or by kicking
the kick starter.
NOTE:
If the engine fails to start when us-
ing the electric starter, release the
start switch, wait a few seconds, then
try again. Each attempt should be as
short as possible to preserve the
battery. Do not crank the engine
more than 5 seconds on any one at-
tempt. If the engine does not start
with the starter motor, kick the kick
starter to start the engine.
NOTE:
For maximum engine life, always
warm up the engine about 1 ~ 3 min-
utes before riding your scooter.
Never accelerate hard with a cold
engine.
EC000046
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See the “Engine break-in” section
prior to operating the motorcycle for
the first time.
OPERATION AND IMPORTANT RIDING POINTS
5-3
EAUT0003
0 ~ 150 km (0 ~ 100 mi)
Avoid operation above 1/3 throttle.
Stop the engine and let it cool for 5
to 10 minutes after every hour of
operation. Vary the speed of the
scooter from time to time. Do not op-
erate it at one set throttle position.
150 ~ 500 km (100 ~ 300 mi)
Avoid prolonged operation above
1/2 throttle.
500 ~ 1,000 km (300 ~ 600 mi)
Avoid cruising speeds in excess of
3/4 throttle.
ECT00060
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After 1,000 km of operation, be sure
to replace the final gear oil.
1,000 km (600 mi) and beyond
Avoid prolonged full throttle opera-
tion. Vary speeds occasionally.
EC000049
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If any engine trouble should occur
during the break-in period, consult
a Yamaha dealer immediately.
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Parking
When parking the scooter, stop the
engine and remove the ignition key.
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The exhaust system is hot. Park the
scooter in a place where pedestri-
ans or children are not likely to
touch the scooter.
Do not park the scooter on a slope
or soft ground the scooter may over-
turn.
6-1
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00464
Periodic inspection, adjustment and
lubrication will keep your scooter in
the safest and most efficient condi-
tion possible. Safety is an obligation
of the scooter owner. The mainte-
nance and lubrication schedule chart
should be considered strictly as a
guide to general maintenance and
lubrication intervals. YOU MUST
TAKE INTO CONSIDERATION THAT
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATIONS, AND A VARIETY
OF INDIVIDUAL USES ALL TEND TO
DEMAND THAT EACH OWNER AL-
TER THIS TIME SCHEDULE TO
SHORTER INTERVALS TO MATCH
THE 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 scooter
service, this work should be done by
a Yamaha dealer.
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This scooter is designed for use on
paved road surface only. If this
scooter is operated in abnormally
dusty, muddy or wet conditions, the
air filter should be cleaned or re-
placed more frequently. Otherwise,
rapid engine wear may result. Con-
sult a Yamaha dealer for proper
maintenance intervals.
EAU00469
Tool kit
The service information included in
this manual is intended to provide
you, the owner, with the necessary
information for completing some of
your own preventive maintenance
and minor repairs.
The tools provided in the owner’s
tool kit are to assist you in the per-
formance of periodic maintenance.
However, some other tools such as
a torque wrench are also necessary
to perform the maintenance cor-
rectly.
1. Tool kit
1
NOTE:
If you do not have necessary tools
required during a service operation,
take your scooter to a Yamaha dealer
for service.
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Modifications to this scooter not ap-
proved by Yamaha may cause loss
of performance, and render it unsafe
for use. Consult a Yamaha dealer be-
fore attempting any changes.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00473
Periodic maintenance and lubrication chart
CHECKS OR MAINTENANCE JOB
*
*
*
*
*
*
*
*
*
1
2
3
4
5
6
7
8
9
10
11
12
ITEMNo. ODOMETER READING(km)
1,000 6,000 12,000 18,000 24,000
ANNUAL
CHECK
9Check 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.
9Lubricate with lithium-soap-based grease.
9Make sure that all nuts, bolts and screws are properly tight-
ened.
9Check operation.
9Lubricate.
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
6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
CHECKS OR MAINTENANCE JOBITEMNo.
13
14
15
16
17
18
19
20
21
22
*
*
*
*
*
*
*
*
Sidestand switch
Front fork
Rear shock absorber
assembly
Carburetor
Autolube pump
Final gear oil
V-belt
Front and rear brake
switches
Moving parts and
cables
Lights, signals and
switches
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.
9Lubricate.
9Check operation.
9Adjust headlight beam.
ODOMETER READING(km)
1,000 6,000 12,000 18,000 24,000
√ √ √ √ √√
√ √ √ √
√ √ √ √
√ √ √√
√ √√
√ √√
√ √ √ √ √√
√ √ √ √ √
√ √ √ √ √√
ANNUAL
CHECK
Every 10,000 km
√ √ √ √ √√
PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
EAU01450
NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake system
9When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the
brake fluid level regularly and fill as required.
9Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
9Replace the brake hoses every four years or if cracked or damaged.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
The ideal color on the white insula-
tor a round the center electrode is a
medium-to-light tan color for a
scooter that is being ridden nor-
mally.
Do not attempt to diagnose such
problems yourself. Instead, take the
scooter to a Yamaha dealer . You
should periodically remove and in-
spect the spark plug because heat
and deposits will cause any spark
plug to slowly break down and
erode. If electrode erosion becomes
excessive, or if carbon and other
deposits are excessive, you should
replace the spark plug.
Specified spark plug:
BPR7HS (NGK)
Installation
1. Measure the electrode gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
Spark plug gap:
0.9 ~ 1.0 mm
2. Clean the gasket surface. Wipe
off any grime from the threads.
3. Install the spark plug and tighten
it to the specified torque, then
replace 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 available
when you are installing a sprark
plug, a good estimate of the correct
torque is 1/4 to 1/2 turn past finger
tight. Have the spark plug tightened
to the specified torque as soon as
possible.
4. Install the panel.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
1. Oil filler cap 1. Drain bolt 1. Carburetor joint clamp
11
1
EAU02961
Final gear oil replacement
1. 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 oil
Final gear oil quantity:
0.13 L
EW000066
w
Do not let foreign material enter the
final gear case. Be sure oil does not
get 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 cleaning
This air filter should be cleaned at
the specified intervals.
It should be cleaned more frequently
if you are riding in unusually wet or
dusty areas.
1. Remove panel B. (Refer to page
6-7 for removal and installation
procedures.)
2. Remove the carburetor joint
clamp.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
EAU00627
Carburetor adjustment
The carburetor is a vital part of the
engine and its emission control sys-
tem. Adjusting should be left to a
Yamaha dealer with the professional
knowledge, specialized data and
equipment to do so properly.
EAU00634
Throttle cable free play
adjustment
NOTE:
Before checking the throttle cable
free play, the engine idling speed
should be adjusted.
Adjust the throttle cable by turning
the adjusting nut so that specified
free play at the throttle grip is ob-
tained.
Free play:
3 ~ 5 mm
7. Apply oil to the entire surface of
the air filter element and
squeeze out the excess oil. It
should be damp, but not drip-
ping.
Recommended oil:
Engine oil
8. Coat the sealing edges of the air
filter case and air filter case
cover lightly with grease for an
airtight seal.
9. Install the air filter element and
the air filter case cover.
10.Install the air filter case and the
carburetor joint clamp.
11.Tighten the air filter case bolt
and the air filter case joint screw.
12.Install the panel.
EC000082
cC
Make sure the air filter is properly
seated in the air filter case.
The engine should never be run
without the air filter installed. Exces-
sive piston and/or cylinder wear
may result.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
EAU00661
Tires
To ensure maximum performance,
long service, and safe operation,
note the following:
Tire air pressure
Always check and adjust the tire
pressure before operating the
scooter.
EW000076
w
Tire inflation pressure should be
checked and adjusted when the
temperature of the tire equals the
ambient 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 this
model), and vehicle speed.
CE-02E
Maximum load*: 160 kg
Cold tire pressure: Front Rear
200 kpa 200 kpa
Up to 90 kg (2.00 kgf/cm
2, (2.00 kgf/cm2,
2.00 bar) 2.00 bar)
90 kg load ~ 200 kpa 200 kpa
Maximum load* (2.00 kgf/cm
2, (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 nut
3. Free play
1
2
a
b
1. Loosen the locknut.
2. Turn the adjusting nut in direc-
tion a to increase free play and
in direction to decrease freeb
play.
3. Tighten the locknut.
EW000086
w
Proper loading of your scooter is im-
portant for several characteristics of
your scooter such as handling, brak-
ing, performance and safety. Do not
carry loosely packed items that can
shift. Securely pack your heaviest
items close to the center of the
scooter, and distribute the weight
evenly from side to side.
Check the condition and pressure of
your tires. NEVER OVERLOAD
YOUR SCOOTER. Make sure the to-
tal weight of the cargo, rider, and
accessories (fairing, saddlebags, etc.
if approved for this model) does not
exceed the maximum load of the
scooter. Operation of an overloaded
scooter could cause tire damage, an
accident, or even injury.
3
PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
Tire inspection
Always check the tires before oper-
ating the scooter. If center tread
depth reaches the limit as shown, if
the tire has a nail or glass fragments
in 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 are
replaced, they must be replaced the
recommended tire. Other rubber
compounds, tread patterns, tube
type tires or different ply rate tires
may result in tire failure and/or
NOTE:
These limits may be different by
regulation from country to country.
If so, conform to the limits specified
by 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 tires
replaced by a Yamaha dealer imme-
diately. Brakes, tires, and related
wheel parts replacement should be
left to a Yamaha Service Technician.
CE-10E
FRONT
Manufacturer Size Type
CHENG-SHIN 120/90-10 56J
REAR
Manufacturer Size Type
CHENG-SHIN 130/90-10 59J
CE-11E
Minimum tire tread
depth 1.6 mm
(front and rear)
1
2
1. Tread depth 2. Side wall
scooter instability.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
EAU00720
Checking the front brake pads
and rear brake shoes
EAU00723
Front brake
Apply the brake and inspect the wear
indicator.
If the wear indicator is ALMOST in
contact with the disc plate, ask a
Yamaha dealer to replace the pads.
EAU00727
Rear brake
Apply the brake and inspect the wear
indicator.
If the indicator reaches the wear limit
line, ask a Yamaha dealer to replace
the shoes.
1. Adjusting nut
1
1. Wear indicator
2. Wear limit line
1
2
1. Wear indicator
2. Brake disk
3. Brake pads
1
2
3
To adjust, turn the adjusting nut
clockwise to reduce play or counter-
clockwise to increase play.
EW000101
w
When it is impossible to make the
proper adjustment, ask a Yamaha
dealer.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
ing leakage and poor brake per-
formance.
Recommended brake fluid:
DOT 4
NOTE:
If DOT 4 is not available, DOT 3 can
be used.
9Refill with the same type of
brake fluid. Mixing fluids may
result in a harmful chemical re-
action and lead to poor brake
performance.
9Be careful that water does not
enter the master cylinder when
refilling. Water will significantly
lower the boiling point of the
fluid and may result in vapor
lock.
9Brake fluid may deteriorate
painted surfaces or plastic parts.
Always clean up spilled fluid im-
mediately.
9Have a Yamaha dealer check the
cause if the brake fluid level
goes down.
EAU00742
Brake fluid replacement
The brake fluid should be replaced
only by trained Yamaha service per-
sonnel. Have the Yamaha dealer re-
place the following components dur-
ing periodic maintenance or when
they are damaged or leaking:
9oil seals (every two years)
9brake hoses (every four years)
EAU00732
Inspecting the brake fluid level
Insufficient brake fluid may let air
enter the brake system, possibly
causing the brakes to become inef-
fective.
Before riding, check that the brake
fluid is above the minimum level and
fill when necessary.
Observe these precautions:
9When checking the fluid level,
make sure the top of the master
cylinder is level by turning the
handlebars.
9Use only the designated quality
brake 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 of
cables may lead to internal rusting
and interfere with the cable move-
ment. Replace damaged cables as
soon as possible to prevent unsafe
conditions.
Lubricate the cables and cable ends.
If a cable does not operate smoothly,
ask a Yamaha dealer to replace it.
Recommended lubricant:
Engine oil
PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
EAU00773
Throttle cable and grip lubri-
cation
The throttle twist grip assembly
should be greased at the time that
the cable is lubricated, since the grip
must be removed to get at the end
of the throttle cable. After removing
the screws, hold the end of the cable
up in the air and put in several drops
of lubricant. With the throttle grip
disassembled, coat the metal surface
of the grip assembly with a suitable
all-purpose grease.
EAU00774
Autolube pump adjustment
The autolube pump is a vital part of
the engine and requires very sophis-
ticated adjustment. Adjusting should
be left to a Yamaha dealer who has
the professional knowledge and ex-
perience to do so.
EAU00781
Brake lever lubrication
Lubricate the pivoting parts of both
brake levers.
Recommended lubricant:
Engine oil
EAU02965
Center and sidestand lubrica-
tion
Lubricate the pivoting and mating
joints.
Check to see that the center and
sidestand move up and down
smoothly.
Recommended lubricant:
Engine oil
EW000114
w
If the center and/or sidestand does
not move smoothly, consult a
Yamaha dealer.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
EAU01144
Wheel bearings
If there is play in the front or rear
wheel hub or if the wheel does not
turn smoothly, have a Yamaha
dealer inspect the wheel bearings.
EAU02939
Front fork inspection
Visual check
EW000115
w
Securely support the scooter so
there is no danger of it falling over.
Check for scratches or damage on
the inner tube and excessive oil leak-
age from the front fork. Operation check
1. Place the scooter on a level
place.
2. Hold the scooter in an upright
position and apply the front
brake.
3. Push down hard on the handle-
bars several times and check if
the fork rebounds smoothly.
EC000098
cC
If any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer.
1. Fuse
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
batteries.
KEEP OUT OF REACH OF CHILDREN.
Battery storage
When the scooter is not used for a
month 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 discharged
battery can cause permanent bat-
tery damage.
Use a battery charger designed for
a sealed-type (MF) battery. Using a
conventional battery charger will
cause battery damage. If you do not
have a sealed-type battery charger,
contact your Yamaha dealer.
Always make sure the connections
are correct when reinstalling the
battery.
EAUT0804
Fuse replacement
The fuse case is located beside the
battery. Remove panel B to access
the battery. (Refer to page 6-7 for
removal and installation proce-
dures.)
If the fuse is blown, turn off the main
switch and all other switches. Install
a new fuse of specified amperage.
Turn on the switches and see if all
electrical devices operate. If the fuse
immediately blows again, consult a
Yamaha dealer.
EC000103
cC
Do not use fuses of higher amper-
age rating than those recom-
mended. Substitution of a fuse of
improper rating can cause extensive
electrical system damage and pos-
sibly a fire.
Specified fuse:
7A
PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
EAUT1528
Headlight bulb replacement
This scooter is equipped with a S1
bulb headlight. If the headlight bulb
burns out, replace it as follows:
1. Remove cowling A. (See page
6-6 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 your
hands away from a bulb while it is
on, as it is hot. Do not touch a bulb
until it cools down.
3. Put a new bulb into position and
secure it in place with the bulb
holder.
EC000105
cC
Avoid touching the glass part of a
bulb. Keep it free from oil; other-
wise, the transparency of the glass,
life of the bulb, and luminous flux
will be adversely affected. If oil gets
on a bulb, thoroughly clean it with
a cloth moistened with alcohol or
lacquer thinner.
4. Install the cowling.
If the headlight beam adjustment is
necessary, ask a Yamaha dealer to
make that adjustment.
EAU00855
Turn signal and taillight bulb
replacement
1. Remove the screws and the
lense.
2. Push the bulb inward and turn
it counterclockwise.
1. Turn signal bulb
Front
1
EAUT1624
License light bulb
replacement
1. Remove the license light cover
by removing the screws.
2. Push the bulb inward and turn
it counterclockwise.
3. Place a new bulb in the socket.
Push the bulb inward and turn
it clockwise until it engages into
the socket.
4. Install the license light cover and
the screws.
1. Taillight bulb 1. Light cover 2. License light bulb
12
EC000108
cC
Do not over-tighten the screws as
the lense may break.
1
PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
1. Turn signal bulb
Rear
1
3. Place a new bulb in the socket.
Push the bulb inward and turn
it clockwise until it engages into
the socket.
4. Install the lense and the screws.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
EAU01008
Troubleshooting
Although Yamaha scooters receive
a rigid inspection before shipment
from the factory, trouble may occur
during operation.
Any problem in the fuel, compres-
sion, or ignition systems can cause
poor starting and loss of power. The
troubleshooting chart describes a
quick, easy procedure for making
checks.
If your scooter requires any repair,
bring it to a Yamaha dealer. The
skilled technicians at a Yamaha deal-
ership have the tools, experience,
and know-how to properly service
your motorcycle. Use only genuine
Yamaha parts on your scooter. Imi-
tation parts may look like Yamaha
parts, but they are often inferior.
Consequently, they have a shorter
service life and can lead to expen-
sive repair bills.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
1. Fuel
2. Compression
3. Ignition
4. Battery
Check connections
or recharge.
Check if there is
fuel in the tank
Enough fuel Go to compression check.
No fuel Supply fuel. Engine doesn’t start, go to
compression check.
Use electric starter.
There is compression. Go to ignition check.
No compression. Ask a Yamaha dealer to inspect.
Remove spark
plug and check
electrode.
Wet Wipe clean with dry cloth and correct
spark gap or replace spark plugs.
Engine doesn’t start, go to battery
check.
Dry Ask a Yamaha dealer to inspect.
Engine turns over
quickly. Battery good.
Engine doesn’t start, ask a Yamaha
dealer to inspect.
Engine turns over
slowly.
Use electric
starter
EAU01397
Troubleshooting chart
EW000125
w
Never check the fuel system while smoking or in the vicinity of an open flame.
9 Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water
to clean plastic.
9 Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake
fluid, antifreeze or electrolyte.
9 Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following
areas: seals (of wheel bearings,
swingarm bearings, bearings,
forks and brakes), electric com-
ponents (couplers, connectors,
instruments, switches and
lights), breather hoses and
vents.
9 For scooters equipped with a
windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure they do not leave any
marks. If the windshield is
scratched, use a quality plastic
polishing compound after
washing.
After riding in the rain, near the sea
or on salt-sprayed roads
Since sea salt or salt sprayed on the
roads in the winter are extremely
corrosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads. (Salt sprayed
in the winter may remain on the
roads well into spring.)
1. Clean your scooter with cold wa-
ter and soap after the engine has
cooled down.
ECA00012
cC
Do not use warm water since it in-
creases the corrosive action of the
salt.
2. Be sure to apply a corrosion pro-
tection spray on all (even
chrome- and nickel-plated)
metal surfaces to prevent corro-
sion.
SCOOTER CARE AND STORAGE
7-2

Specyfikacje produktu

Marka: Yamaha
Kategoria: skuter
Model: BW100 (2005)

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