check engine light YAMAHA MAJESTY 180 2006 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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Use caution when adding electri-
cal accessories. If electrical
accessories exceed the capacity
of the scooter’s electrical system
an electric failure could result,
which could cause a dangerous
loss of lights or engine power.
Gasoline and exhaust gas
GASOLINE IS HIGHLY FLAMMA-
BLE:
• Always turn the engine off
when refueling.
• Take care not to spill any gaso-
line on the engine or exhaust
system when refueling.
• Never refuel while smoking or
in the vicinity of an open flame.
Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within
a short time. Always operate your
scooter in an area that has ade-
quate ventilation.
Always turn the engine off before
leaving the scooter unattended
and remove the key from the
main switch. When parking the
scooter, note the following:
• The engine and exhaust sys-
tem may be hot, therefore,
park the scooter in a place
where pedestrians or children
are not likely to touch these hot
areas.
• Do not park the scooter on a
slope or soft ground, otherwise
it may fall over.
• Do not park the scooter near a
flammable source (e.g., a kero-
sene heater, or near an open
flame), otherwise it could catch
fire.
If you should swallow any gasoli-
ne, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immedia-
tely. If any gasoline spills on your
skin or clothing, immediately
wash the affected area with soap
and water and change your clot-
hes.
EAU10360
Further safe-riding points
Be sure to signal clearly when
making turns.
Braking can be extremely difficult
on a wet road. Avoid hard bra-
king, because the scooter could
slide. Apply the brakes slowly
when stopping on a wet surface.
Slow down as you approach a
corner or turn. Once you have
completed a turn, accelerate
slowly.
Be careful when passing parked
cars. A driver might not see you
and open a door in your path.
Railroad crossings, streetcar
rails, iron plates on road cons-
truction sites, and manhole
covers become extremely slip-
pery when wet. Slow down and
cross them with caution. Keep
the scooter upright, otherwise it
could slide out from under you.
The brake lining could get wet
when you wash the scooter. After
washing the scooter, check the
brakes before riding.
1
tSAFETY INFORMATION
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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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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
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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)
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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
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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)
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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
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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)
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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)
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