engine YAMAHA MAJESTY 250 2003 User Guide

3-23
INSTRUMENT AND CONTROL FUNCTIONS
3
The sidestand switch may be defective.
The scooter should not be ridden until
checked by a Yamaha dealer.YES NO
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “#”.
3. Turn the key to “ON”.
4. Keep the front or rear brake applied.
5. Push the start switch.
Does the engine start?
The brake switch may be defective.
The scooter should not be ridden until
checked by a Yamaha dealer.
With the engine still off:
6. Move the sidestand up.
7. Keep the front or rear brake applied.
8. Push the start switch.
Does the engine start?
With the engine still running:
9. Move the sidestand down.
Does the engine stall?
The sidestand switch may be defective.
The scooter should not be ridden until
checked by a Yamaha dealer.
NOTE:
This check is most reliable if performed with
a warmed-up engine.
YES NO
The system is OK. The scooter can be ridden.
YES NO
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4-1
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PRE-OPERATION CHECKS
4The condition of a vehicle is the owner’s 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.
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Pre-operation check listPre-operation check list
ITEM CHECKS PAGE
Fuel•Check fuel level in fuel tank.
•Refuel if necessary.
•Check fuel line for leakage.3-5, 3-16– 3-17
Engine oil•Check oil level in engine.
•If necessary, add recommended oil to specified level.
•Check vehicle for oil leakage.6-14–6-17
Final transmission oil•Check vehicle for oil leakage. 6-18–6-19
Coolant•Check coolant level in reservoir.
•If necessary, add recommended coolant to specified level.
•Check cooling system for leakage.3-5, 6-19–6-20
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.3-11, 6-27–6-30
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OPERATION AND IMPORTANT RIDING POINTS
Starting the engine ............................................................................5-1
Starting off .........................................................................................5-2
Acceleration and deceleration ...........................................................5-3
Braking ..............................................................................................5-3
Tips for reducing fuel consumption ....................................................5-4
Engine break-in .................................................................................5-4
Parking ..............................................................................................5-5
5
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3
2
1
1. Start switch
2. Front brake lever
3. Rear brake lever
5-1
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OPERATION AND IMPORTANT RIDING POINTS
5
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8 8
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or func-
tion that you do not thorough-
ly understand.
8 8
Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
8 8
For safety, always start the
engine with the centerstand
down.
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Starting the engineStarting the engineEC000046
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See page 5-4 for engine break-in
instructions prior to operating the
vehicle for the first time.
In order for the ignition circuit cut-off
system to enable starting, the side-
stand must be up.
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8 8
Before starting the engine,
check the function of the igni-
tion circuit cut-off system
according to the procedure
described on page 3-23.
8 8
Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch
is set to “#”.
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When the key is turned to “ON”,
the ABS warning light should
come on for a few seconds, and
then go off. If the ABS warning
light does not come on or remains
on, have a Yamaha dealer inspect
the electrical circuit.
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5-2
OPERATION AND IMPORTANT RIDING POINTS
5 2. Close the throttle completely.
3. Start the engine by pushing the
start switch while applying the
front or rear brake.
NOTE:
If the engine does not start, release
the start switch, wait a few seconds,
and then try again. Each starting
attempt should be as short as possi-
ble to preserve the battery. Do not
crank the engine more than 10 sec-
onds on any one attempt. If the
engine does not start, try with the
throttle open 1/8 turn.
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For maximum engine life, never
accelerate hard when the engine is
cold!
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Starting off
Starting offNOTE:
Before starting off, allow the engine
to warm up.
1. While pulling the rear brake lever
with your left hand and holding
the grab bar with your right hand,
push the scooter off the center-
stand.
2. Sit astride the seat, and then
adjust the rear view mirrors.
3. Switch the turn signal on.4. Check for oncoming traffic, and
then slowly turn the throttle grip
(on the right) in order to take off.
5. Switch the turn signal off.
1
1. Grab bar
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5-4
OPERATION AND IMPORTANT RIDING POINTS
5
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Tips for reducing fuel
consumption
Fuel consumption, tips for reducingFuel consumption depends largely on
your riding style. Consider the follow-
ing tips to reduce fuel consumption:
8Avoid high engine speeds during
acceleration.
8Avoid high engine speeds with
no load on the engine.
8Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at
traffic lights or at railroad cross-
ings).
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Engine break-inEngine break-inThere is never a more important peri-
od in the life of your engine than the
period between 0 and 1,600 km. For
this reason, you should read the fol-
lowing material carefully.
Since the engine is brand new, do
not put an excessive load on it for the
first 1,600 km. The various parts in
the engine wear and polish them-
selves to the correct operating clear-
ances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheat-
ing must be avoided.
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0–1,000 km
Avoid prolonged operation above
4,000 r/min.
1,000–1,600 km
Avoid prolonged operation above
5,000 r/min.
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After 1,000 km of operation, be
sure to replace the engine oil and
final transmission oil.
1,600 km and beyond
The vehicle can now be operated
normally.
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8
8
Keep the engine speed below
8,500 r/min.
8 8
If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the vehi-
cle.
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5-5
OPERATION AND IMPORTANT RIDING POINTS
5
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ParkingParkingWhen parking, stop the engine, and
then remove the key from the main
switch.
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8 8
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely
to touch them.
8 8
Do not park on a slope or on
soft ground, otherwise the
scooter may overturn.
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Never park in an area where there
are fire hazards such as grass or
other flammable materials.
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PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit ....................................................6-1
Periodic maintenance and lubrication chart .........6-3
Removing and installing the cowlings and
panel .................................................................6-6
Checking the spark plug ....................................6-12
Engine oil ...........................................................6-14
Final transmission oil .........................................6-18
Coolant ..............................................................6-19
Air filter and V-belt case air filter elements ........6-21
Air flow louver ....................................................6-23
Adjusting the throttle cable free play .................6-23
Adjusting the valve clearance ...........................6-23
Tires ...................................................................6-24
Cast wheels .......................................................6-26
Adjusting the front and rear brake lever
free play ..........................................................6-27
Checking the front and rear brake pads ............6-28
Checking the brake fluid level ............................6-29
Changing the brake fluid ....................................6-30
Checking and lubricating the cables ..................6-30
Checking and lubricating the throttle grip
and cable ........................................................6-31
Lubricating the front and rear brake levers ........6-31Checking and lubricating the centerstand
and sidestand .................................................6-31
Checking the front fork ......................................6-32
Checking the steering ........................................6-33
Checking the wheel bearings ............................6-33
Removing the battery cover ...............................6-34
Battery ...............................................................6-34
Replacing the fuses ...........................................6-36
Replacing a headlight bulb ................................6-37
Replacing a front turn signal light bulb ..............6-39
Replacing a rear turn signal light bulb ...............6-40
Replacing a tail/brake light bulb .........................6-40
Replacing the license plate light bulb ................6-41
Troubleshooting .................................................6-42
Troubleshooting charts ......................................6-43
6
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6-1
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. The most important
points of inspection, adjustment, and
lubrication are explained on the fol-
lowing pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a
general guide under normal riding
conditions. However, DEPENDING
ON THE WEATHER, TERRAIN,
GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTE-
NANCE INTERVALS MAY NEED TO
BE SHORTENED.
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Owner’s tool kitTool kitThe owner’s tool kit is located inside
the rear storage compartment. (See
page 3-20 for the rear storage com-
partment opening procedures.)
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If you are not familiar with scooter
maintenance work, have a Yamaha
dealer do it for you.
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This scooter is designed for use
on paved roads only. If this scoot-
er is operated in abnormally dusty,
muddy or wet conditions, the air
filter element should be cleaned or
replaced more frequently, other-
wise rapid engine wear may result.
Consult a Yamaha dealer for prop-
er maintenance intervals.
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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 3-3 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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