maintenance YAMAHA MAJESTY 180 2006 User Guide

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

and then blow the remaining dirt
out with compressed air.
5. Check the air filter element for
damage and replace it if neces-
sary.
6. Insert the air filter element into
the air filter case.
7. Install the air filter case cover by
installing the screws.
Cleaning the V-belt case air filter
element
1. V-belt case air filter cover
2. Screw (x 3)
3. Air filter element
1. Remove the V-belt case air filter
cover by removing the screws.
2. Remove the air filter element, and
then blow out the dirt with com-
pressed air as shown.3. Check the air filter element for
damage and replace it if neces-
sary.
4. Install the air filter element with
the colored side facing outward.
5. Install the V-belt case air filter
cover by installing the screws.
ECA10530
CAUTION
Make sure that each filter ele-
ment is properly seated in its
case.
The engine should never be
operated without the filter ele-
ments installed, otherwise the
piston(s) and/or cylinder(s)
may become excessively worn.
EAU21300
Adjusting the carburetor
The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, all car-
buretor adjustments should be left to
a Yamaha dealer, who has the neces-
sary professional knowledge and
experience.
EAU21381
Checking the throttle cable
free play
The throttle cable free play should
measure 1,5~3,0 mm (0,060~0,118 in)
at the throttle grip. Periodically check
the throttle cable free play and, if
necessary, have a Yamaha dealer
adjust it.
1
23
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
5XL-F8199-E3.qxd 19/09/2005 16:26 Página 41

EAU21540
Tires
To maximize the performance, durabi-
lity, and safe operation of your
motorcycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be chec-
ked and, if necessary, adjusted befo-
re each ride.
EWA10500
s s
WARNING
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperatu-
re of the tires equals the
ambient temperature).
The tire air pressure must be
adjusted in accordance with
the riding speed and with thetotal weight of rider, passenger,
cargo, and accessories appro-
ved for this model.
EWA11020
s s
WARNING
Because loading has an enormous
impact on the handling, braking,
performance and safety characte-
ristics of your motorcycle, you
should keep the following precau-
tions in mind.
NEVER OVERLOAD THE
MOTORCYCLE! Operation of
an overloaded motorcycle may
result in tire damage, loss of
control, or severe injury. Make
sure that the total weight of
rider, passenger, cargo, and
accessories does not exceed
the specified maximum load
for the vehicle.
Do not carry along loosely pac-
ked items, which can shift
during a ride.
Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.
Adjust the suspension and tire
air pressure with regard to the
load.
Check the tire condition and air
pressure before each ride.
Tire air pressure (measured on
cold tires):
Up to 90 kg (198 lb):
Front:
190 kPa (27,02 psi)
(1,9 kgf/cm
2)
Rear:
220 kPa (31,29 psi)
(2,2 kgf/cm
2)
90 kg (198 lb) to maximum load:
Front:
190 kPa (27,02 psi)
(1,9 kgf/cm
2)
Rear:
240 kPa (34,14 psi)
(2,4 kgf/cm
2)
Maximum load*:
183 kg (403,51 lb)
* Total weight of rider, passenger, car-
go and accessories
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
5XL-F8199-E3.qxd 19/09/2005 16:26 Página 42

Tire inspection
1. Depth
2. Side face
The tires must be checked before
each ride. If the center tread depth
reaches the specified limit, if the tire
has a nail or glass fragments in it, or if
the sidewall is cracked, have a Yama-
ha dealer replace the tire immediately.
NOTE:
The tire tread depth limits may differ
from country to country. Always
comply with the local regulations.
Tire information
This motorcycle is equipped with tube
tires.
EWA10460
s s
WARNING
The front and rear tires should
be of the same make and
design, otherwise the handling
characteristics of the vehicle
cannot be guaranteed.
After extensive tests, only the
tires listed below have been
approved for this model by
Yamaha Motor España, S.A.
EWA10570
s s
WARNING
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding
stability and can lead to loss of
control.
The replacement of all wheel-
and brake-related parts, inclu-
ding the tires, should be left to
a Yamaha dealer, who has the
necessary professional know-
ledge and experience.
It is not recommended to patch
a punctured tube. If unavoida-
ble, however, patch the tube
very carefully and replace it as
soon as possible with a high-
quality product.Front tire:
Size:
120/70-12 51L
Manufacturer/model:
MICHELIN
CHENG SING
PIRELLI
Rear tire:
Size:
130/70-12 56L
Manufacturer/model:
MICHELIN
CHENG SING
PIRELLI
Minimum tire tread depth (front
and rear):
1.6 mm (0.06 in)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
5XL-F8199-E3.qxd 19/09/2005 16:26 Página 43

EAU22100
Adjusting the brake lever
free play
(b) Free play 2 ~ 5 mm
(d) Free play 2 ~ 5 mm
The brake lever free play should mea-
sure 2~5 mm (0,079~0,197 in) as
shown. Periodically check the brake
lever free play and, if necessary, have
a Yamaha dealer adjust it.
EWA10640
s s
WARNING
An incorrect brake lever free play
indicates a hazardous condition in
the brake system. Do not operate
the motorcycle until the brake sys-
tem has been checked or repaired
by a Yamaha dealer.
EAU22340
Checking the front and rear
brake pads
1. Wear limit
The front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart. To check the
brake pad wear, measure the lining
thickness. If the lining thickness is
less than 0,5 mm (0,02 in), have a
Yamaha dealer replace the brake
pads as a set.
EAU22580
Checking the brake fluid
level
1. Minimum level
Insufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake
fluid is above the minimum level mark
and replenish if necessary. A low bra-
ke fluid level may indicate worn brake
pads and/or brake system leakage. If
the brake fluid level is low, be sure to
check the brake pads for wear and
the brake system for leakage.
1
1
RearFront
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
5XL-F8199-E3.qxd 19/09/2005 16:26 Página 44

Observe these precautions:
When checking the fluid level,
make sure that the top of the bra-
ke fluid reservoir is level.
Use only the recommended qua-
lity brake fluid, otherwise the rub-
ber seals may deteriorate, cau-
sing leakage and poor braking
performance.
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performan-
ce.
Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vapor
lock.
Brake fluid may deteriorate pain-
ted surfaces or plastic parts.
Always clean up spilled fluid
immediately.
As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if
the brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
EAUM1360
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the brake
hose replaced every four years or
whenever it is damaged or leaking.
EAU23100
Checking and lubricating the
cables
The operation of all control cables
and the condition of the cables
should be checked before each ride,
and the cables and cable ends should
be lubricated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or repla-
ce it.
EWA10720
s s
WARNING
Damage to the outer sheath may
interfere with proper cable opera-
tion and will cause the inner cable
to rust. Replace a damaged cable
as soon as possible to prevent
unsafe conditions.
Recommended lubricant:
Engine oil
Recommended brake fluid:
DOT 4
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
5XL-F8199-E3.qxd 19/09/2005 16:26 Página 45

EAU23210
Checking and lubricating the
centerstand and sidestand
The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-
to-metal contact surfaces should be
lubricated if necessary.
EWA10740
s s
WARNING
If the centerstand or sidestand
does not move up and down smo-
othly, have a Yamaha dealer check
or repair it.
EAU23271
Checking the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the perio-
dic maintenance and lubrication
chart.
To check the condition
EWA10750
s s
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and
rebounds smoothly.
ECA10590
CAUTION
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
Recommended lubricant:
Lithium-soap-based grease (all-
purpose grease)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
5XL-F8199-E3.qxd 19/09/2005 16:26 Página 46

EWA10750
s s
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the stee-
ring.
EAU23290
Checking the wheel bearings
The front and rear wheel bearings
must be checked at the intervals spe-
cified in the periodic maintenance and
lubrication chart. If there is play in the
wheel hub or if the wheel does not
turn smoothly, have a Yamaha dealer
check the wheel bearings.
EAU23320
Battery
1. Battery
A poorly maintained battery will
corrode and discharge quickly. The
electrolyte level, battery lead connec-
tions and breather hose routing
should be checked before each ride
and at the intervals specified in the
periodic maintenance and lubrication
chart.To check the electrolyte level
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion.
NOTE:
Make sure that the vehicle is positio-
ned straight up when checking the
electrolyte level.
2. Remove cowling A. (See page 6-5)
3. Check the electrolyte level in the
battery.
NOTE:
The electrolyte should be between
the minimum and maximum level
marks.
4. If the electrolyte is at or below the
minimum level mark, add distilled
water to raise it to the maximum
level mark.
1
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
5XL-F8199-E3.qxd 19/09/2005 16:26 Página 47