oil YAMAHA MAJESTY 180 2005 Owners Manual

SAFETY INFORMATION.....................1-1
DESCRIPTION.....................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and Instruments .................2-3
INSTRUMENT AND CONTROL
FUNCTION..........................................3-1
Main switch.......................................3-1
Indicator lights ..................................3-1
Speedometer unit .............................3-3
Battery voltage/fuel gauge ...............3-3
Clock .................................................3-4
Handlebar switches ..........................3-4
Front brake lever...............................3-5
Rear brake lever................................3-6
Fuel tank cap ....................................3-6
Fuel ...................................................3-6
Seat...................................................3-7
Front storage compartment..............3-7
Storage compartment.......................3-7
Adjusting the rear shock absorber
assemblies.....................................3-8
Sidestand ..........................................3-8
Sidestand switch operation check ...3-9
PRE-OPERATION CHECKS...............4-1
Pre-operation check list....................4-2OPERATION AND IMPORTANT RIDING
POINTS................................................5-1
Starting a cold engine ......................5-1
Starting off ........................................5-2
Acceleration and deceleration ..........5-2
Braking..............................................5-2
Parking ..............................................5-3
PERIODIC MAINTENANCE AND
MINOR REPAIRS................................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and
lubrication chart ............................6-2
Removing and installing cowlings
and panels .....................................6-5
Checking the spark plug ..................6-6
Engine oil ..........................................6-7
Final gear oil .....................................6-9
Coolant ...........................................6-10
Air filter and V-belt case air filter
elements ......................................6-11
Adjusting the carburetor .................6-12
Checking the throttle cable free
play ..............................................6-12
Tires ................................................6-13
Adjusting the brake lever free
play ..............................................6-15
Checking the front and rear brake
pads.............................................6-15
Checking the brake fluid level ........6-15
Changing the brake fluid ................6-16Checking and lubricating the
cables ..........................................6-16
Checking and lubricating the
centerstand and sidestand .........6-17
Checking the front fork ...................6-17
Checking the steering.....................6-17
Checking the wheel bearings .........6-18
Battery ............................................6-18
Replacing the fuse ..........................6-20
Replacing the headlight bulb or
a front turn signal light bulb ........6-20
Replacing a front turn signal light
bulb .............................................6-21
Replacing the license plate light
bulb .............................................6-21
Replacing the tail/brake light bulb
or a rear turn signal light bulb .....6-22
Troubleshooting ..............................6-23
Troubleshooting chart .....................6-24
SCOOTER CARE AND STORAGE.....7-1
Care ..................................................7-1
Storage .............................................7-3
SPECIFICATIONS...............................8-1
CONSUMER INFORMATION.............9-1
Identification numbers ......................9-1
TABLE OF CONTENTS
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EAU10420
Right view
DESCRIPTION
2-2
2
7. Passenger handle
8. Rear shock absorber (page 3-8)
9. Seat (page 3-7)
10. Engine oil dipstick (page 6-7)11. Storage compartment (page 3-7)
12. Battery/fuse box (page 6-18)
13. Coolant reservoir (page 6-10)
14. Radiator
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EAU11030
Turn signal indicator lights “c” and
“
d”
The corresponding indicator light flas-
hes when the turn signal switch is
pushed to the left or right.
EAU11080
High beam indicator light “j”
This indicator light comes on when
the high beam of the headlight is swit-
ched on.
EAU11390
Oil change indicator light “z”
1. Oil change indicator
2. Coolant temperature warning light
This indicator light comes on at the
initial 1000 km (600 mi) and every
3000 km (1800 mi) thereafter to indi-cate that the engine oil should be
changed.
If the engine oil is changed before the
oil change indicator comes on (i.e.
before the periodic oil change interval
has been reached), the indicator light
must be reset after the oil change for
the next periodic oil change to be
indicated at the correct time. (See
page 6-8.)
The electrical circuit of the indicator
light can be checked according to the
following procedure.
1. Set the engine stop switch to “h”
and turn the key to “ON”.
2. Check that the indicator comes
on for a few seconds and then
goes off.
3. If the indicator light does not
come on, have a Yamaha dealer
check the electrical circuit.
NOTE:
The oil change indicator light may
flash when the engine is revved with
the scooter on the centerstand, but
this does not indicate a malfunction.
EAUM1080
Coolant temperature warning light
“
y”
This warning light comes on when the
engine overheats. When this occurs,
stop the engine immediately and
allow the engine to cool.
The electrical circuit of the warning
light can be checked according to the
following procedure.
1. Turn the key to “h”.
2. If the warning light does not
come on, have a Yamaha dealer
check the electrical circuit.
ECA10020
CAUTION
Do not operate the engine if it is
overheated.
12
3
INSTRUMENT AND CONTROL FUNCTIONS
3-2
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EAU15603
Pre-operation check list
PRE-OPERATION CHECKS
4-2
4
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
Fuel• Refuel if necessary. 3-3, 3-6
• Check fuel line for leakage.
• Check oil level in engine.
Engine oil• If necessary, add recommended oil to specified level. 6-7
• Check vehicle for oil leakage.
Final transmission oil• Check vehicle for oil leakage. 6-9
• Check coolant level in reservoir.
Coolant• If necessary, add recommended coolant to specified level. 6-10
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Front brake• Replace if necessary. 3-5, 6-15
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Rear brake• Replace if necessary. 3-6, 6-15
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Make sure that operation is smooth.
Throttle grip• Check cable free play.
5-2, 6-12
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.
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Keep in mind that braking on a
wet road is much more difficult.
Ride slowly down a hill, as bra-
king downhill can be very diffi-
cult.
EAU16830
Engine break-in
There is never a more important
period in the life of your engine than
the period between 0 and 1000 km
(600 mi). For this reason, you should
read the following material carefully.
Since the engine is brand new, do not put
an excessive load on it for the first 1000
km (600 mi). The various parts in the engi-
ne wear and polish themselves to the
correct operating clearances. During this
period, prolonged full-throttle operation
or any condition that might result in engi-
ne overheating must be avoided.
EAU17150
0~150 km (0~90 mi)
Avoid prolonged operation above 1/3
throttle.
After every hour of operation, stop the
engine, and then let it cool for five to
ten minutes.Vary the engine speed from time to
time. Do not operate the engine at
one set throttle position.
150~500 km (90~300 mi)
Avoid prolonged operation above 1/2
throttle.
Rev the engine freely through the
gears, but do not use full throttle at
any time.
500~1000 km (300~600 mi)
Avoid prolonged operation above 3/4
throttle.
ECA10370
CAUTION
After 1000 km (600 mi) of operation,
the transmission oil must be chan-
ged.
1000 km (600 mi) and beyond
Avoid prolonged full-throttle opera-
tion. Vary the engine speed occasio-
nally.
ECA10270
CAUTION
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
EAU17200
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10310
s s
WARNING
Since the engine and exhaust
system can become very hot,
park in a place where pedes-
trians or children are not likely
to touch them.
Do not park on a slope or on
soft ground, otherwise the
vehicle may overturn.5
OPERATION AND IMPORTANT RIDING POINTS
5-3
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ODOMETER READING (x 1000 Km) ANNUAL
CHECK
NoITEM CHECK OR MAINTENANCE JOB 1 10 20 30 40
9 * Rear brake • Check operation, fluid level and vehicle for fluid leakage.√√ √ √√ √
•Replace brake pads. Whenever worn to the limit
10 * Wheels • Check runout and for damage.√√√√
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 24000 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 • Check operation and shock absorbers for oil leakage.√√√√
assemblies
18 * Carburetor • Adjust engine idling speed.√√ √ √√ √
19 Engine oil • Change. (See page *-*.)√When the oil change
indicator light comes on (every 3000 km)
• Check oil level and vehicle for oil leakage. Every 3000 km√
20 * Engine oil strainer • Clean.√
21 * Cooling system • Check coolant level and vehicle for coolant leakage.√√√√ √
• Change. Every 3 years
22 Final gear oil • Check oil level and vehicle for oil leakage.√√ √
• Change.√√√
23 * V-belt • Replace. Every 10000 km
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
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EAUS1241
Engine oil
1. Dipstick
(a) Maximum level (b) Minimum level
The engine oil level should be chec-
ked before each ride. In addition, the
oil must be changed at the intervals
specified in the periodic maintenance
and lubrication chart and when the oil
change indicator light comes on.
To check the engine oil level
1. Place the vehicle on the centers-
tand.
NOTE:
Make sure that the vehicle is positio-
ned straight up when checking the oil
level. A slight tilt to the side can result
in a false reading.
2. Start the engine, warm it up for
several minutes, and then turn it off.
3. Wait a few minutes until the oil
settles, remove the oil filler cap,
wipe the dipstick clean, insert it
back into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
NOTE:
The engine oil should be between the
minimum and maximum level marks.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to rai-
se it to the correct level.
5. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.To change the engine oil
1. Drainage cap
1. Start the engine, warm it up for
several minutes, and then turn it off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and the engine oil drain bolt to
drain the oil from the crankcase.
ECA10410
CAUTION
When removing the engine oil drain
bolt, the O-ring, spring, and oil
strainer will fall out. Take care not
to lose these parts.
1
1a
b
6
PERIODIC MAINTENANCE AND MINOR REPAIR
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1. O-ring
2. Compression spring
3. Strainer
4. Clean the oil strainer with solvent,
and then check it for damage and
replace it if necessary.
5. Check the O-ring for damage and
replace it if necessary.
6. Install the oil strainer, spring, O-
ring and engine drain bolt, and
then tighten the drain bolt to the
specified torque.
NOTE:
Make sure that the O-ring is properly
seated.
7. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil
filler cap.
ECA11670
CAUTION
Do not use oils with a diesel
specification of “CD” or oils of
a higher quality than specified.
In addition, do not use oils
labeled “ENERGY CONSER-
VING II” or higher.
Be sure no foreign material
enters the crankcase.
8. Start the engine, and then let it
idle for several minutes while
checking it for oil leakage. If oil is
leaking, immediately turn the
engine off and check for the cau-
se.
9. Reset the oil change indicator
light according to the following
procedure.To reset the oil change indicator
light
1. Push and hold the “TRIP” button
for a MAXIMUM of three
seconds. While pushing the
“TRIP” button, turn the key to
“f”.
2. Release the “TRIP” button and
the oil change indicator light will
go off.
3. Turn the key to “e”.
NOTE:
If the engine oil is changed before the
oil change indicator light comes on
(i.e. before the periodic oil change
interval has been reached), the indi-
cator light must be reset after the oil
change for the next periodic oil chan-
ge to be indicated at the correct time.
To reset the oil change indicator light
before the periodic oil change interval
has been reached, follow the above
procedure, but note that the indicator
light will come on for 1.4 seconds
after releasing the reset button, other-
wise repeat the procedure.
Recommended engine oil:
See page 8-1.
Oil change quantity:
1,3 L (0,286 US qt) (1,144 Imp.qt)
Tightening torque:
Engine oil drain bolt:
32 Nm (3,2 m•kgf, 23,15ft•lb)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU20011
Final gear oil
1. Oil filler cap
The final gear case must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha dea-
ler check and repair the vehicle. In
addition, the final gear oil must be
changed as follows at the intervals
specified in the periodic maintenance
and lubrication chart.
EWA10370
s s
WARNING
Make sure that no foreign
material enters the final gear
case.
Make sure that no oil gets on
the tire or wheel.
To check the final gear oil level
1. Place the vehicle on the centers-
tand.
1. Drain bolt
NOTE:
The final gear oil level must be
checked on a cold engine.
Make sure that the vehicle is posi-
tioned straight up when checking
the oil level. A slight tilt to the side
can result in a false reading.
2. Remove the oil filler bolt, and
then check the oil level in the final
gear case.
NOTE:
The oil level should be at the brim of
the filler hole.
3. If the oil is below the brim of the
filler hole, add sufficient oil of the
recommended type to raise it to
the correct level.
4. Install the oil filler bolt, and then
tighten it to the specified torque.
To change the final gear oil
1. Place an oil pan under the final
gear case to collect the used oil.
2. Remove the oil filler bolt and
drain bolt to drain the oil from the
final gear case.
3. Install the final gear oil drain bolt,
and then tighten it to the speci-
fied torque.
Tightening torque:
Final gear oil filler bolt:
22 Nm (2,2 m•kgf, 15,91 ft•lbf)
1
1
6
PERIODIC MAINTENANCE AND MINOR REPAIR
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4. Add the recommended final gear
oil to the brim of the filler hole.
5. Install the oil filler bolt, and then
tighten it to the specified torque.
6. Check the final gear case for oil
leakage. If oil is leaking, check for
the cause.
EAU20070
Coolant
1. Maximum level
2. Minimum level
The coolant level should be checked
before each ride. In addition, the coo-
lant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAUS1080
To check the coolant level
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion.
NOTE:
The coolant level must be chec-
ked on a cold engine since the
level varies with engine tempera-
ture.
Make sure that the vehicle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
1. Coolant tank cap
2. Check the coolant level through
the check window.
NOTE:
The coolant should be between the
minimum and maximum level marks.
1
1
2
Recommended final gear oil:
Shaft drive gear oil (Part No.:
9079E-SH001-00)
Oil quantity:
0,15 L (0,033 US qt) (0,132 Imp.qt)
Tightening torque:
Final gear oil drain bolt:
22 Nm (2,2 m•kgf, 15,91 ft•lbf)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
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