YAMAHA MAJESTY 250 2003 Workshop Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit ....................................................6-1
Periodic maintenance and lubrication chart .........6-3
Removing and installing the cowlings and
panel .................................................................6-6
Checking the spark plug ....................................6-12
Engine oil ...........................................................6-14
Final transmission oil .........................................6-18
Coolant ..............................................................6-19
Air filter and V-belt case air filter elements ........6-21
Air flow louver ....................................................6-23
Adjusting the throttle cable free play .................6-23
Adjusting the valve clearance ...........................6-23
Tires ...................................................................6-24
Cast wheels .......................................................6-26
Adjusting the front and rear brake lever
free play ..........................................................6-27
Checking the front and rear brake pads ............6-28
Checking the brake fluid level ............................6-29
Changing the brake fluid ....................................6-30
Checking and lubricating the cables ..................6-30
Checking and lubricating the throttle grip
and cable ........................................................6-31
Lubricating the front and rear brake levers ........6-31Checking and lubricating the centerstand
and sidestand .................................................6-31
Checking the front fork ......................................6-32
Checking the steering ........................................6-33
Checking the wheel bearings ............................6-33
Removing the battery cover ...............................6-34
Battery ...............................................................6-34
Replacing the fuses ...........................................6-36
Replacing a headlight bulb ................................6-37
Replacing a front turn signal light bulb ..............6-39
Replacing a rear turn signal light bulb ...............6-40
Replacing a tail/brake light bulb .........................6-40
Replacing the license plate light bulb ................6-41
Troubleshooting .................................................6-42
Troubleshooting charts ......................................6-43
6
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6-1
EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. The most important
points of inspection, adjustment, and
lubrication are explained on the fol-
lowing 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 MAINTE-
NANCE INTERVALS MAY NEED TO
BE SHORTENED.
EAU03623
Owner’s tool kitTool kitThe owner’s tool kit is located inside
the rear storage compartment. (See
page 3-20 for the rear storage com-
partment opening procedures.)
EW000060
w
If you are not familiar with scooter
maintenance work, have a Yamaha
dealer do it for you.
EAU00466
w
This scooter is designed for use
on paved roads only. If this scoot-
er is operated in abnormally dusty,
muddy or wet conditions, the air
filter element should be cleaned or
replaced more frequently, other-
wise rapid engine wear may result.
Consult a Yamaha dealer for prop-
er maintenance intervals.
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6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
6 Pull up the mat, and then remove the
owner’s tool kit.
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended to
assist you in the performance of pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be nec-
essary to perform certain mainte-
nance work correctly.
2
1
1. Mat
2. Owner’s tool kit
NOTE:
If you do not have the tools or experi-
ence required for a particular job,
have a Yamaha dealer perform it for
you.
EW000063
w
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle
unsafe for use. Consult a Yamaha
dealer before attempting any
changes.
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6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03685
Periodic maintenance and lubrication chartPeriodic maintenance and lubrication chartNOTE:
8 8
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
8Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line•Check fuel hoses and vacuum hose for cracks or damage.√√√√ √
2 Spark plug•Check condition.
•Clean and regap.√√
•Replace.√√
3
*Valves•Check valve clearance.
•Adjust.√√
4 Air filter element•Clean.√√
•Replace.√√
5V-belt case air filter
element•Clean.√√√√
6
*Front brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)√√√√√ √
•Replace brake pads.Whenever worn to the limit
7
*Rear brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)√√√√√ √
•Replace brake pads.Whenever worn to the limit
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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6
8*Brake hoses•Check for cracks or damage.√√√√ √
•Replace. (See NOTE on page 6-5.)Every 4 years
9
*Wheels•Check runout and for damage.√√√√
10
*Tires•Check tread depth and for damage.
•Replace if necessary.
•Check air pressure.
•Correct if necessary.√√√√ √
11
*Wheel bearings•Check bearing for looseness or damage.√√√√
12
*Steering bearings•Check bearing play and steering for roughness.√√√√√
•Lubricate with lithium-soap-based grease.Every 20,000 km
13
*Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.√√√√ √
14 Sidestand, centerstand•Check operation.
•Lubricate.√√√√ √
15
*Sidestand switch•Check operation.√√√√√ √
16
*Front fork•Check operation and for oil leakage.√√√√
17
*Shock absorber
assemblies•Check operation and shock absorbers for oil leakage.√√√√
18
*Carburetor•Adjust engine idling speed.√√√√√ √
19 Engine oil•Change. (See page 3-3 and 6-17 for more information
about the oil change indicator light.)√When the oil change indicator light comes on
(every 3,000 km)
•Check oil level and vehicle for oil leakage.Every 3,000 km√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
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6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03884
NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinders and calipers, and change the
brake fluid.
9Replace the brake hoses every four years and if cracked or damaged.
20*Engine oil strainer•Clean.√
21
*Cooling system•Check coolant level and vehicle for coolant leakage.√√√√ √
•Change.Every 3 years
22 Final transmission oil•Check vehicle for oil leakage.√√ √
•Change.√√√
23
*V-belt•Replace.Every 20,000 km
24
*Front and rear brake
switches•Check operation.√√√√√ √
25 Moving parts and cables•Lubricate.√√√√ √
26
*Throttle grip housing
and cable•Check operation and free play.
•Adjust the throttle cable free play if necessary.
•Lubricate the throttle grip housing and cable.√√√√ √
27
*Lights, signals and
switches•Check operation.
•Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
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6-6
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Removing and installing the
cowlings and panel
Cowlings and panel, removing and installingThe cowlings and panel shown above
need to be removed to perform some
of the maintenance jobs described in
this chapter. Refer to this section
each time a cowling or the panel
needs to be removed and installed.
1
1. Cowling A
1
1. Cowling C
1
1. Cowling B
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6-7
PERIODIC MAINTENANCE AND MINOR REPAIR
6
1
1. Panel A
2. Remove the cowling screws.
2 11
1. Screw (×4)
2. Cowling A
EAU03615
Cowling ACowling *To remove the cowling
1. Pull up the left floorboard mats
as shown.
1
2
1. Mat A
2. Mat B
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6-8
PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. Pull the cowling down slightly,
and then pull it outward as
shown.
EAU03632
Cowling BCowling *To remove the cowling
1. Pull up the right floorboard mats
as shown.
1
2
1. Mat A
2. Mat B
To install the cowling
1. Insert the tabs on the cowling
into the slots as shown, and then
install the screws.
2. Place the floorboard mats in the
original position.
ECA00067
cC
Take care not to damage the tabs
on the cowling when removing and
or installing it.
1
1. Tab (×10)
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6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
62. Remove the screws.
2 1
1
1. Screw (×4)
2. Cowling B
To install the cowling
1. Insert the tabs on the cowling
into the slots as shown, and then
install the screws.
2. Place the floorboard mats in the
original position.
ECA00067
cC
Take care not to damage the tabs
on the cowling when removing and
or installing it.
1
1. Tab (×10)
3. Pull the cowling down slightly,
and then pull it outward as
shown.
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