YAMAHA MAJESTY 250 2002 Manual PDF

6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03627
Air filter and V-belt case air
filter elementsAir filter and V-belt case air filter elements, cleaningThe 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 and/or cylinder may
become excessively worn.
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.1
2 2
3
4
1. Air filter case cover
2. Screw (×5)
3. Sponge material
4. Mesh sheet
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.
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6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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
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.2
1
1. V-belt case air filter cover
2. Screw (×3)
4. Blow the dirt out of the air filter
element with compressed 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.
2
1
1. V-belt case air filter cover
2. V-belt case air filter element
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6-23
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03094
Air flow louverAir 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.
ECA00049
cCBe sure to close the louver when
riding in the rain and when wash-
ing the scooter.
12
b
3a
1. Air flow louver
2. Air inlet
3. Lever
EAU00637
Adjusting the valve
clearanceValve clearance, adjustingThe valve clearance changes with
use, resulting in improper air-fuel mix-
ture and/or engine noise. To prevent
this from occurring, the valve clear-
ance must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
EAU00635
Adjusting the throttle cable
free playThrottle cable free play, adjustingThe throttle cable free play should
measure 3–5 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
a
a. Throttle cable free play
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6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04551
TiresTiresTo 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.
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.
Maximum load* 185 kg
* Total weight of rider, passenger, cargo and
accessories
Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg
175 kPa
(1.75kgf/cm
2,
1.75 bar)200 kPa
(2.00 kgf/cm
2,
2.00 bar)
90 kg load–maximum
200 kPa(2.00 kgf/cm
2,
2.00 bar)225 kPa
(2.25 kgf/cm
2,
2.25 bar)
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6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
68Adjust the suspension and tire
air pressure with regard to the
load.
8Check the tire condition and
air pressure before each ride.
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.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.
1a
1. Sidewall
a. Tire tread depthMinimum tire tread depth
(front and rear)1.6 mm
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00683
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.
NOTE:
The tire tread depth limits may differ
from country to country. Always com-
ply with the local regulations.Tire information
This scooter is equipped with tube-
less tires.FRONT
Manufacturer Size Model
IRC 110/90-12 64L MB67
MICHELIN 110/90-12 64L BOPPER
REAR
Manufacturer Size Model
IRC 130/70-12 62L MB67
MICHELIN 130/70-12 62L BOPPER
EAU03773
Cast wheelsWheelsTo 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.
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EAU00703
Adjusting the front and rear
brake lever free playFront and rear brake lever free play, adjustingThe front and rear brake lever free
play should measure 2–5 mm as
shown. Periodically check the front
and rear brake lever free play and, if
necessary, adjust them as follows.
a b
c 1
2
1. Locknut
2. Adjusting bolt
c. Brake lever free play
6-27
PERIODIC MAINTENANCE AND MINOR REPAIR
6
FRONT
8Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for
it to develop its optimal charac-
teristics.
1. 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
c
a
b
2
1. Locknut
2. Adjusting bolt
c. Brake lever free playREAR
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6-28
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00721
Checking the front and rear
brake padsFront and rear brake pads, checkingThe front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU04583
Front brake pads
Each front brake pad is provided with
a wear indicator groove, which allows
you to check the brake pad wear
without having to disassemble the
brake. Check the brake pad wear as
follows.
1. Remove the brake caliper bolt,
and then tilt the caliper forward
to inspect the wear indicator
groove. If a brake pad has worn
to the point that the wear indica-
tor groove has almost disap-
peared, have a Yamaha dealer
replace the brake pads as a set.
1
2
1. Brake caliper bolt
2. Brake caliperFRONT
2. Install the brake caliper bolt, and
then tighten it to the specified
torque.
1
1. Wear indicator groove (×2)
Tightening torque:
Brake caliper bolt:
26.5 Nm (2.65 m·kgf)
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Observe these precautions:
8When checking the fluid level,
make sure that the top of the
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
1. Minimum level mark
6-29
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03294
Checking the brake fluid
levelBrake fluid level, checkingInsufficient 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
1. Minimum level mark
EAU03939
Rear brake pads
Each rear 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 indicator groove. 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
1. Wear indicator groove (×2)REAR
FRONT
REARRecommended brake fluid:
DOT 4
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6-30
PERIODIC MAINTENANCE AND MINOR REPAIR
6 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 brake fluid reservoir
when refilling. Water will signifi-
cantly 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.
EAU03976
Changing the brake fluidBrake fluid, changingHave a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addi-
tion, have the oil seals of the master
cylinders and calipers as well as the
brake hoses replaced at the intervals
listed below or whenever they are
damaged or leaking.
8Oil seals: Replace every two
years.
8Brake hoses: Replace every four
years.
EAU02962
Checking and lubricating the
cablesCables, checking and lubricatingThe 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 replace it.
EW000112
wDamage 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
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