engine YAMAHA MAJESTY 180 2006 User Guide

EAU16760
Starting off
1. Passenger handle
NOTE:
Before starting off, allow the engine to
warm up.
1. While pulling the rear brake lever
with your left hand and holding
the grab bar with your right hand,
push the scooter off the centers-
tand.
2. Sit astride the seat, and then
adjust the rear view mirrors.
3. Switch the turn signal on.
4. Check for oncoming traffic, and
then slowly turn the throttle grip
(on the right) in order to take off.
5. Switch the turn signal off.
EAU16780
Acceleration and
deceleration
The speed can be adjusted by ope-
ning and closing the throttle. To incre-
ase the speed, turn the throttle grip in
direction (a). To reduce the speed,
turn the throttle grip in direction (b).
EAU16791
Braking
1. Close the throttle completely.
2. Apply both front and rear brakes
simultaneously while gradually
increasing the pressure.
EWA10300
s s
WARNING
Avoid braking hard or suddenly
(especially when leaning over
to one side), otherwise the sco-
oter may skid or overturn.
Railroad crossings, streetcar rails,
iron plates on road construction
sites, and manhole covers beco-
me extremely slippery when wet.
Therefore, slow down when
approaching such areas and
cross them with caution.
1
5
OPERATION AND IMPORTANT RIDING POINTS
5-2
5XL-F8199-E3.qxd 19/09/2005 16:26 Página 28

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
5XL-F8199-E3.qxd 19/09/2005 16:26 Página 29

EAU17280
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 follo-
wing 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, GEO-
GRAPHICAL LOCATION, AND INDIVI-
DUAL USE, THE MAINTENANCE
INTERVALS MAY NEED TO BE
SHORTENED.
EWA10320
s s
WARNING
If you are not familiar with mainte-
nance work, have a Yamaha dealer
do it for you.
EWA10330
s s
WARNING
This scooter is designed for use on
paved roads only. If this scooter is
operated in abnormally dusty,
muddy or wet conditions, the air fil-
ter element should be cleaned or
replaced more frequently, otherwi-
se rapid engine wear may result.
Consult a Yamaha dealer for proper
maintenance intervals.
EAU17320
Owner’s tool kit
1. Owner’s tool kit
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended toassist you in the performance of pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be
necessary to perform certain mainte-
nance work correctly.
NOTE:
If you do not have the tools or expe-
rience required for a particular job,
have a Yamaha dealer perform it for
you.
EWA10350
s s
WARNING
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 chan-
ges.
1
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-1
5XL-F8199-E3.qxd 19/09/2005 16:26 Página 30

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
5XL-F8199-E3.qxd 19/09/2005 16:26 Página 32

EAU19620
Checking the spark plug
1. Spark plug cap
The spark plug is an important engine
component, which should be chec-
ked periodically, preferably by a
Yamaha dealer. Since heat and depo-
sits will cause any spark plug to
slowly erode, it should be removed
and checked in accordance with the
periodic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
The porcelain insulator around the
center electrode of the spark plug
should be a medium-to-light tan (the
ideal color when the vehicle is riddennormally). If the spark plug shows a
distinctly different color, the engine
could be defective. Do not attempt to
diagnose such problems yourself.
Instead, have a Yamaha dealer check
the vehicle.
If the spark plug shows signs of elec-
trode erosion and excessive carbon
or other deposits, it should be repla-
ced.
1. Spark plug wrench
Before installing a spark plug, the
spark plug gap should be measured
with a wire thickness gauge and, if
necessary, adjusted to specification.Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
1. Spark plug gap
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4~1/2 turn past finger tight. Howe-
ver, the spark plug should be tighte-
ned to the specified torque as soon
as possible.
Tightening torque:
Spark plug:
20 Nm 2,0 m•kgf, 14,46ft•lb)
Spark plug gap:
0,7~0,8 mm (0,0275in-0,0315in)
Specified spark plug:
CR8E (NGK)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
5XL-F8199-E3.qxd 19/09/2005 16:26 Página 35

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
6-7
5XL-F8199-E3.qxd 19/09/2005 16:26 Página 36

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
6-8
5XL-F8199-E3.qxd 19/09/2005 16:26 Página 37

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
6-9
5XL-F8199-E3.qxd 19/09/2005 16:26 Página 38

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
5XL-F8199-E3.qxd 19/09/2005 16:26 Página 39

3. If the coolant is at or below the
minimum level mark, remove the
front cowling by removing the
screws.
4. Open the reservoir cap, and then
add coolant to the maximum
level mark.
ECA10470
CAUTION
If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
If water has been used instead
of coolant, replace it with coo-
lant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the coo-
ling system will not be protec-
ted against frost and corrosion.
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possi-
ble, otherwise the effective-
ness of the coolant will be
reduced.
5. Close the reservoir cap, and then
install the front cowling by insta-
lling the screws.
EAUM1320
Air filter and V-belt case air
filter elements
The air filter and the V-belt case air fil-
ter elements should be cleaned at the
intervals specified in the periodic
maintenance and lubrication chart.
Clean both filter elements more fre-
quently if you are riding in unusually
wet or dusty areas.Cleaning the air filter element
1. Air filter case cover
2. Screw (x 1)
1. Place the scooter on the centers-
tand.
2. Remove the air filter case cover
by removing the screws.
3. Pull the air filter element out.
1. Air filter
4. Lightly tap the air filter element to
remove most of the dust and dirt,
1
1
2
Coolant reservoir capacity:
0,45 L (0,099 US qt) (0,396 Imp.qt)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
5XL-F8199-E3.qxd 19/09/2005 16:26 Página 40