oil level YAMAHA MAJESTY 250 2000 Owners Manual

DESCRIPTION
12
3
4
5
6
7
8
9
2-2
9.Passenger seat
10.Rider seat(page 3-11)
11.Air flow louver(page 6-22)
12.Headlight (page 6-34)
13.Radiator14.Battery(page 6-31)
15.Fuse box(page 6-33)
16.Coolant reservoir cap (page 6-19)
17.Coolant level check window (page 6-19)
18.Engine oil filler cap(page 6-15)
10
11
12
13 16 17
1815, 14
9
Right view
5GM-9-E1(No ABS) 9/27/00 2:18 PM Page 13

4-1
EAU01114
PRE-OPERATION CHECKS
1
2
34
5
6
7
8
9The condition of a vehicle is the ownerÕs responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
EAU03439
Pre-operation check list
ITEMCHECKSPAGE
Fuel¥Check fuel level in fuel tank.
¥Refuel if necessary.
¥Check fuel line for leakage.3-4, 3-9Ð3-10
Engine oil¥Check oil level in engine.
¥If necessary, add recommended oil to specified level.
¥Check vehicle for oil leakage.6-14Ð6-17
Final gear oil¥Check vehicle for oil leakage.6-17Ð6-18
Coolant¥Check coolant level in reservoir.
¥If necessary, add recommended coolant to specified level.
¥Check cooling system for leakage.3-4, 6-18Ð6-20
Front brake¥Check operation.
¥If soft or spongy, have Yamaha dealer bleed hydraulic system.
¥Check lever free play.
¥Adjust if necessary.
¥Check fluid level in reservoir.
¥If necessary, add recommended brake fluid to specified level.
¥Check hydraulic system for leakage.3-8, 6-25Ð6-28
5GM-9-E1(No ABS) 9/27/00 2:18 PM Page 34

PERIODIC MAINTENANCE AND MINOR REPAIR
OwnerÕs tool kit.......................................................6-1
Periodic maintenance and lubrication chart............6-3
Removing and installing cowlings and panel..........6-6
Checking the spark plug.......................................6-12
Engine oil..............................................................6-14
Final gear oil.........................................................6-17
Coolant..................................................................6-18
Air filter and V-belt case air filter elements...........6-20
Air flow louver.......................................................6-22
Tires......................................................................6-23
Wheels..................................................................6-25
Adjusting the front and rear brake lever
free play..............................................................6-25
Checking the front and rear brake pads................6-26
Checking the brake fluid level...............................6-27
Changing the brake fluid.......................................6-28
Checking and lubricating the cables.....................6-28
Lubricating the front and rear brake levers...........6-28
Checking and lubricating the
centerstand and sidestand..................................6-29
Checking the front fork..........................................6-29
Checking the steering...........................................6-30
Checking the wheel bearings................................6-31
Removing the battery cover..................................6-31Battery...................................................................6-31
Replacing the fuses..............................................6-33
Replacing a headlight bulb....................................6-34
Replacing a front turn signal light bulb..................6-35
Replacing a rear turn signal light bulb...................6-36
Replacing a tail/brake light bulb............................6-37
Replacing the license plate light bulb....................6-37
Troubleshooting....................................................6-38
Troubleshooting charts.........................................6-39
6
5GM-9-E1(No ABS) 9/27/00 2:18 PM Page 43

6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
9
*Wheels¥Check runout and for damage.ÖÖÖÖ
10*Tires¥Check tread depth and for damage.
¥Replace if necessary.
¥Check air pressure.
¥Correct if necessary.ÖÖÖÖ
11*Wheel bearings¥Check bearing for looseness or damage.ÖÖÖÖ
12*Steering bearings¥Check bearing play and steering for roughness.ÖÖÖÖÖ
¥Lubricate with lithium-soap-based greaseEvery 20,000km
13*Chassis fasteners¥Make sure that all nuts, bolts and screws are properly tightened.ÖÖÖÖÖ
14Sidestand/centerstand¥Check operation.
¥Lubricate.ÖÖÖÖÖ
15*Sidestand switch¥Check operation.ÖÖÖÖÖÖ
16*Front fork¥Check operation and for oil leakage.ÖÖÖÖ
17*Rear shock absorber
assemblies¥Check operation and shock absorbers for oil leakage.ÖÖÖÖ
18*Carburetor¥Check starter (choke) operation.
¥Adjust engine idling speed.ÖÖÖÖÖÖ
19Engine oil¥Change when the oil change indicator light comes on. (See
page 3-2 and 6-17.)ÖEvery 3,000 km
20*Engine oil strainer¥Clean.ÖÖÖ
21*Cooling system¥Check coolant level and vehicle for coolant leakage.ÖÖÖÖÖ
¥Change.Every 3 years NO.ITEMCHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
110203040
5GM-9-E1(No ABS) 9/27/00 2:18 PM Page 47

6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU03541
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 cylinder and caliper, and change the brake
fluid.
9Replace the brake hoses every four years and if cracked or damaged.22Final gear oil¥Check vehicle for oil leakage.ÖÖÖ
¥Change.ÖÖÖ
23
*V-belt¥Replace.ÖÖ
24*Front and rear brake
switches¥Check operation.ÖÖÖÖÖÖ
25Moving parts and cables¥Lubricate.ÖÖÖÖÖ
26*Lights, signals and
switches¥Check operation.
¥Adjust headlight beam.ÖÖÖÖÖÖ NO.ITEMCHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
110203040
5GM-9-E1(No ABS) 9/27/00 2:18 PM Page 48

6-14
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4Ð1/2 turn past finger tight.
However, the spark plug should be
tightened to the specified torque as
soon as possible.4.Install the spark plug cap.
5.Install the cowling. Tightening torque:
Spark plug:
17.5 Nm (1.75 m0kg)
EAU03119
Engine oilThe engine oil level should be
checked before each ride. In addition,
the oil must be changed at the inter-
vals specified in the periodic mainte-
nance and lubrication chart and when
the oil change indicator light comes
on.To check the engine oil level
1.Place the scooter on the center-
stand.
NOTE:
Make sure that the scooter is posi-
tioned 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.
5GM-9-E1(No ABS) 9/27/00 2:18 PM Page 57

6-15
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
93.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 (with-
out 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.
3121
1.Engine oil filler cap
2.Maximum level mark
3.Minimum level mark
4.If the engine oil is below the min-
imum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
5.Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.

1
1.Engine oil drain boltTo change the engine oil
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.
5GM-9-E1(No ABS) 9/27/00 2:18 PM Page 58

6-17
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
1
To reset the oil change indicator
light
1.Turn the key to ÒONÓ.
2.Hold the reset button pushed for
two to five seconds.
3.Release the reset button, and
the oil change indicator light will
go off.1.Reset button
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
change 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 but-
ton, otherwise repeat the procedure.
EAU03469
Final gear oilThe final gear case must be checked
for oil leakage before each ride. If
any leakage is found, have a
Yamaha dealer check and repair the
scooter. In addition, the final gear oil
must be changed as follows at the
intervals specified in the periodic
maintenance and lubrication chart.
1.Start the engine, warm it up by
riding the scooter for several
minutes, and then stop the
engine.
2.Place the scooter on the center-
stand.NOTE:
Make sure that the scooter is posi-
tioned straight up when checking the
oil level. A slight tilt to the side can
result in a false reading.3.Place an oil pan under the final
gear case to collect the used oil.
5GM-9-E1(No ABS) 9/27/00 2:18 PM Page 60

4.Remove the oil filler cap and
drain bolt to drain the oil from the
final gear case.
5.Install the final gear oil drain bolt,
and then tighten it to the speci-
fied torque.
6.Add the specified amount of the
recommended final gear oil, and
then install and tighten the oil
filler cap.
6-18
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
1
1.Final gear oil filler cap
Tightening torque:
Final gear oil drain bolt:
22 Nm (2.2 m0kg)
EW000066
w8Make sure that no foreign
material enters the final gear
case.
8Make sure that no oil gets on
the tire or wheel.7.Check the final gear case for oil
leakage. If oil is leaking, check
for the cause.
1
1.Final gear oil drain bolt
Recommended final gear oil:
See page 8-2.
Oil quantity:
0.25 L
EAU01587
CoolantThe coolant reservoir is located
under the battery cover. (See page
6-31 for battery cover removal proce-
dures.)
To check the coolant level
1.Place the scooter on a level sur-
face and hold it in an upright
position.NOTE:
8The coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
8Make sure that the scooter is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
5GM-9-E1(No ABS) 9/27/00 2:18 PM Page 61

6-27
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
1
Observe these precautions:
8When checking the fluid level,
make sure that the top of the
master cylinder or brake fluid
reservoir is level.
8Use only the recommended qual-
ity brake fluid, otherwise the rub-
ber seals may deteriorate, caus-
ing leakage and poor braking
performance.1.Minimum level markREARRecommended brake fluid:
DOT 4
8Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking perfor-
mance.
8Be careful that water does not
enter the master cylinder or
brake fluid reservoir when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.
8Brake fluid may deteriorate paint-
ed surfaces or plastic parts.
Always clean up spilled fluid
immediately.
8As 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.
1
EAU03607
Checking the brake fluid
levelInsufficient 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
brake fluid level may indicate worn
brake pads and/or brake system
leakage. If the brake level is low, be
sure to check the brake pads for
wear and the brake system for leak-
age.1.Minimum level mark FRONT
5GM-9-E1(No ABS) 9/27/00 2:18 PM Page 70