i searched web for defective keyboards - none available - i also spoke to another yamaha keyboard engineer who advised me to try some "contact lubricant cleaner" on the volume control knob (remove and spray the pot).
i will give this a go?
any suggestions would be welcome.
Yes, give it a try but be careful with spray's as mentioned before, NOWHERE near rubbery parts and it gives only temporary solutions (if at all).
If it is the pot, yes it is possible! It's not too bad. Try move it forward and backward for 30 second with the keyboard OFF. If it is dirt or burnt in on the 'coal'track it might clean it and work again (for a short while) but at least you've tried it.
However if it is the potentiometer you should have noticed it earlier by noise when moving it up or down. Check also the connections of the pot, it is a stereo type and if one connection is loose or has a bad soldering it can give the problem you have..
Guessing of course again.
Good luck John.
DickR