YAMAHA MAJESTY 250 2001 Repair Manual

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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.
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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.
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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.
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2.Check the coolant level in the
coolant reservoir.NOTE:
The coolant should be between the
minimum and maximum level marks.1.Maximum level mark
2.Minimum level mark
1
1.Coolant reservoir cap3.If the coolant is at or below the
minimum level mark, open the
reservoir cap, add coolant to the
maximum level mark, and then
close the reservoir cap.
4.Install the battery cover. Coolant reservoir capacity:
0.4 L
EC000080
cC8If 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.
8If water has been used instead
of coolant, replace it with
coolant as soon as possible,
otherwise the engine may not
be sufficiently cooled and the
cooling system will not be pro-
tected against frost and corro-
sion.
8If 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.
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NOTE:
The radiator fan is automatically
switched on or off according to the
coolant temperature in the radiator. If
the engine overheats, see page 6-40
for further instructions.
Cleaning the air filter element
1.Place the scooter on the center-
stand.
2.Remove the air filter case cover
by removing the screws.
3.Pull the sponge material out
along with the mesh sheet, clean
it with solvent, and then squeeze
the remaining solvent out.
EAU03627
Air filter and V-belt case air
filter elementsThe air filter and V-belt case air filter
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.
EC000092
cC8Make sure that each filter ele-
ment is properly seated in its
case.
8The engine should never be
operated without the filter ele-
ments installed, otherwise the
piston(s) and/or cylinder(s)
may become excessively
worn.
1
2 2
3
4
1.Air filter case cover
2.Screw (´5)
3.Sponge material
4.Mesh sheet
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NOTE:
The sponge material should be wet
but not dripping.7.Insert the sponge material into
the air filter case.
8.Install the air filter case cover by
installing the screws. Recommended oil:
Engine oil
4.Check the sponge material for
damage and replace it if neces-
sary.
5.Allow the sponge material to dry.
6.Apply oil of the recommended
type to the entire surface of the
sponge material, and then
squeeze the excess oil out.
2
1
1.V-belt case air filter cover
2.Screw (´3)Cleaning the V-belt case air filter
element
1.Remove cowling A (See page
6-7 for cowling removal and
installation procedures.)
2.Remove the air filter case cover
by removing the screws.
3.Remove the V-belt case air filter
cover by removing the screws.
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1.V-belt case air filter cover
2.V-belt case air filter element4.Blow the dirt out with com-
pressed air as shown.
5.Check the V-belt case air filter
element for damage and replace
it if necessary.
6.Install the V-belt case air filter
element cover by installing the
screws.
7.Install the air filter case cover by
installing the screws.
8.Install the cowling.
EAU03094
Air flow louverOpening the air flow louver may help
reduce air turbulence.
To open the air flow louver
Move the lever in direction a.
To close the air flow louver
Move the lever in direction b.
12
b3
a
1.Air flow louver
2.Air inlet
3.Lever
ECA00049
cCBe sure to close the louver when
riding in the rain and when wash-
ing the scooter.
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EW000077
wBecause loading has an enormous
impact on the handling, braking,
performance and safety character-
istics of your scooter, you should
keep the following precautions in
mind.
8NEVER OVERLOAD THE
SCOOTER! Operation of an
overloaded scooter may result
in tire damage, loss of control,
or severe injury. Make sure
that the total weight of rider,
cargo, and accessories does
not exceed the specified maxi-
mum load for the vehicle.
8Do not carry along loosely
packed items, which can shift
during a ride.
8Securely pack the heaviest
items close to the center of the
scooter and distribute the
weight evenly on both sides.
8Adjust the suspension and tire
air pressure with regard to the
load.
EW000082
w8The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the tempera-
ture of the tires equals the
ambient temperature).
8The tire air pressure must be
adjusted in accordance with
the riding speed and with the
total weight of rider, passen-
ger, cargo, and accessories
approved for this model.
Tire air pressure
(measured on cold tires)
Load*FrontRear
Up to 90 kg
175 kPa
(1.75kg/cm
2,
1.75 bar)200 kPa
(2.00 kg/cm
2,
2.00 bar)
90 kgÐmaximum
200 kPa
(2.00 kg/cm
2,
2.00 bar)225 kPa
(2.25 kg/cm
2,
2.25 bar)
Maximum load*187 kg
*Total weight of rider, passenger, cargo and
accessories
EAU00675
TiresTo maximize the performance, dura-
bility, and safe operation of your
scooter, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
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9 8Check the tire condition and
air pressure before each ride.
1a
Tire inspection
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
Yamaha dealer replace the tire imme-
diately.1.Side wall
a.Tread depth
NOTE:
The tire tread depth limits may differ
from country to country. Always com-
ply with the local regulations.
EW000079
w8Have a Yamaha dealer replace
excessively worn tires.
Besides being illegal, operat-
ing the scooter with exces-
sively worn tires decreases
riding stability and can lead to
loss of control.
8The replacement of all wheel-
and brake-related parts,
including the tires, should be
left to a Yamaha dealer, who
has the necessary profession-
al knowledge and experience.
Minimum tire tread depth
(front and rear)1.6 mm
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EAU00687
WheelsTo maximize the performance, dura-
bility, and safe operation of your
scooter, note the following points
regarding the specified wheels.
8The wheel rims should be
checked for cracks, bends or
warpage before each ride. If any
damage is found, have a
Yamaha dealer replace the
wheel. Do not attempt even the
smallest repair to the wheel. A
deformed or cracked wheel must
be replaced.
8The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.
8Ride at moderate speeds after
changing a tire since the tire sur-
face must first be Òbroken inÓ for
it to develop its optimal charac-
teristics.
1
2
a
c
b
EAU00703
Adjusting the front and rear
brake lever free playThe front and rear brake lever free
play should measure 2Ð5 mm as
shown. Periodically check the front
and rear brake lever free play and, if
necessary, adjust them as follows.1.Locknut
2.Adjusting bolt
c.Brake lever free play FRONT
Tire information
This scooter is equipped with tube-
less tires.FRONT
ManufacturerSizeType
INOUE110/90-12 64LMB67
MICHELIN110/90-12 64LBOPPER
REAR
ManufacturerSizeType
INOUE130/70-12 62LMB67
MICHELIN130/70-12 62LBOPPER
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a
c
b1.Loosen the locknut at the brake
lever.
2.To increase the brake lever free
play, turn the adjusting bolt in
direction a. To decrease the
brake lever free play, turn the
adjusting bolt in direction b.
3.Tighten the locknut.
EW000101
wIf proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this adjust-
ment.1.Locknut
2.Adjusting bolt
c.Brake lever free play REAR
1
If a brake pad has worn to the point
that the wear indicator groove has
almost disappeared, have a Yamaha
dealer replace the brake pads as a
set.1.Wear indicator groove (´2)REAR
1
1.Wear indicator groove (´2) FRONT
EAU01314
Checking the front and rear
brake padsThe front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart. Each brake pad
is provided with a wear indicator
groove, which allows you to check
the brake pad wear without having to
disassemble the brake. To check the
brake pad wear, check the wear indi-
cator grooves.
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