engine YAMAHA MAJESTY 250 2002 Owner's Manual

6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6
8
*Brake hoses•Check for cracks or damage.√√√√ √
•Replace. (See NOTE on page 6-5.)Every 4 years
9*Wheels•Check runout and for damage.√√√√
10*Tires•Check tread depth and for damage.
•Replace if necessary.
•Check air pressure.
•Correct if necessary.√√√√ √
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 20,000 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
assemblies•Check operation and shock absorbers for oil leakage.√√√√
18*Carburetor•Adjust engine idling speed.√√√√√ √
19 Engine oil•Change. (See page 3-2 and 6-17 for more information
about the oil change indicator light.)√When the oil change indicator light comes on
(every 3,000 km)
•Check oil level and vehicle for oil leakage.Every 3,000 km√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
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6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
6
20
*Engine oil strainer•Clean.√
21*Cooling system•Check coolant level and vehicle for coolant leakage.√√√√ √
•Change.Every 3 years
22 Final transmission oil•Check vehicle for oil leakage.√√ √
•Change.√√√
23*V-belt•Replace.Every 20,000 km
24*Front and rear brake
switches•Check operation.√√√√√ √
25 Moving parts and cables•Lubricate.√√√√ √
26*Throttle grip housing
and cable•Check operation and free play.
•Adjust the throttle cable free play if necessary.
•Lubricate the throttle grip housing and cable.√√√√ √
27*Lights, signals and
switches•Check operation.
•Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
EAU03884
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 cylinders and calipers, and change the
brake fluid.
9Replace the brake hoses every four years and if cracked or damaged.
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6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
6 To install the panel
Place the panel in the original posi-
tion, and then install the bolts.
1
1
1. Tab (×4)
To remove the spark plug
1. Remove cowling B. (See page
6-8 for cowling removal and
installation procedures.)
2. Remove the spark plug cap.
1
1. Spark plug cap
EAU03620
Checking the spark plugSpark plug, checkingThe spark plug is an important
engine component, which is easy to
check. Since heat and deposits will
cause any spark plug to slowly erode,
the spark plug 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.
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6-13
PERIODIC MAINTENANCE AND MINOR REPAIR
63. Remove the spark plug as
shown, with the spark plug
wrench included in the owner’s
tool kit.
1
1. Spark plug wrench
To install the spark plug
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
a
a. Spark plug gap
To check the spark plug
1. Check that the porcelain insula-
tor around the center electrode
of the spark plug is a medium-to-
light tan (the ideal color when the
scooter is ridden normally).NOTE:
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
scooter.2. Check the spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and
replace it if necessary.
Specified spark plug:
DR8EA (NGK)
Spark plug gap:
0.6–0.7 mm
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6-14
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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.
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.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.
EAU03119
Engine oilEngine 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. Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf)
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6-15
PERIODIC MAINTENANCE AND MINOR REPAIR
63. 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
To 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.
1
1. Engine oil drain bolt
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.
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6-16
PERIODIC MAINTENANCE AND MINOR REPAIR
6 4. Check the washer for damage
and replace it if necessary.
5. Install the washer and the engine
oil drain bolt, and then tighten
the drain bolt to the specified
torque.
NOTE:
Make sure that the washer is properly
seated.
12
1. Engine oil drain bolt
2. Washer
7. 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
cause.
8. Reset the oil change indicator
light according to the following
procedure. 6. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil
filler cap.
EC000030
cC8Do not put in any chemical
additives or use oils with a
grade of CD or higher. Also, be
sure not to use oils labeled
“ENERGY CONSERVING
II” or
higher.
8Be sure no foreign material
enters the crankcase.
Tightening torque:
Engine oil drain bolt:
20 Nm (2.0 m0kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Periodic oil change:
1.2 L
Total amount (dry engine):
1.4 L
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6-17
PERIODIC MAINTENANCE AND MINOR REPAIR
6To reset the oil change indicator
light
1. Turn the key to “ON”.
1
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.
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.
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6-18
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04228
Final transmission oilFinal transmission oilThe final transmission 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 trans-
mission oil must be changed as fol-
lows 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.
3. Place an oil pan under the final
transmission case to collect the
used oil.4. Remove the oil filler cap and
drain bolt to drain the oil from the
final transmission case.
5. Install the final transmission oil
drain bolt, and then tighten it to
the specified torque.
6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten
the oil filler cap.
1
1. Final tramsmission oil filler cap
EWA00062
w8Make sure that no foreign
material enters the final trans-
mission case.
8Make sure that no oil gets on
the tire or wheel.
1
1. Final transmission oil drain bolt
Tightening torque:
Final transmission oil drain bolt:
22 Nm (2.2 m·kgf)
Recommended final transmission
oil:
See page 8-2.
Oil quantity:
0.25 L
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6-19
PERIODIC MAINTENANCE AND MINOR REPAIR
67. Check the final transmission
case for oil leakage. If oil is leak-
ing, check for the cause.
EAU04591
CoolantCoolantThe coolant reservoir is located
under the battery cover. (See page
6-34 for battery cover removal and
installation procedures.)
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.
2. Check the coolant level in the
coolant reservoir.NOTE:
The coolant should be between the
minimum and maximum level marks.
1
2
1. Maximum level mark
2. Minimum level mark
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