check engine YAMAHA MAJESTY 250 2003 Owner's Manual

6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03627
Air filter and V-belt case air
filter elements
Air 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
cC
8
8
Make sure that each filter ele-
ment is properly seated in its
case.
8 8
The engine should never be
operated without the filter ele-
ments installed, otherwise the
piston and/or cylinder may
become excessively worn.
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.
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
34
1. Air filter case cover
2. Screw (×5)
3. Sponge material
4. Mesh sheet
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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.
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.
21
1. V-belt case air filter cover
2. V-belt case air filter element
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.
21
1. V-belt case air filter cover
2. Screw (×3)
Recommended oil:
Engine oil
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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
cC
Be 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
clearance
Valve 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 play
Throttle 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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6-30
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 or dust
does not enter the brake fluid
reservoir when refilling. Water
will significantly lower the boiling
point of the fluid and may result
in vapor lock, and dirt may clog
the ABS hydraulic unit valves.
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.
EAU02962
Checking and lubricating the
cables
Cables, 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
w
Damage 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.
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.Recommended lubricant:
Engine oil
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6-33
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00794
Checking the steeringSteering, checkingWorn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Place a stand under the engine
to raise the front wheel off the
ground.
EW000115
w
Securely support the scooter so
that there is no danger of it falling
over.
EAU01144
Checking the wheel bearingsWheel bearings, checkingThe front and rear wheel bearings
must be checked at the intervals
specified in the periodic maintenance
and lubrication chart. If there is play
in the wheel hub or if the wheel does
not turn smoothly, have a Yamaha
dealer check the wheel bearings.
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any
free play can be felt, have a
Yamaha dealer check or repair
the steering.
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6-43
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01581
Troubleshooting chartsTroubleshooting chartsStarting problems or poor engine performanceEW000125
w
Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level in
the fuel tank.
1. FuelThere is enough fuel.
There is no fuel.Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.
2. CompressionThere is compression.
There is no compression.Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.
3. IgnitionWipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.
4. BatteryThe engine turns over
quickly.
The engine turns over
slowly.The battery is good.
Check the battery lead connections,
and charge the battery if necessary.
Dry
WetOpen the throttle halfway and operate
the electric starter.
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6-44
PERIODIC MAINTENANCE AND MINOR REPAIR
6 Engine overheating
EW000070
w
8 8
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
8 8
After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the
hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the
cap.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.
Wait until the
engine has cooled.Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.
The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.
Add coolant. (See NOTE.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
There is
leakage.
There is
no leakage.
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INDEX
D
Display, multi-function ............................3-5
E
Engine break-in ......................................5-4
Engine oil ..............................................6-14
F
Final transmission oil ............................6-18
Front and rear brake lever free play,
adjusting ...........................................6-27
Front and rear brake pads, checking ....6-28
Front fork, checking ..............................6-32
Fuel ......................................................3-16
Fuel consumption, tips for reducing .......5-4
Fuel gauge .............................................3-5
Fuel tank cap ........................................3-15
Fuses, replacing ...................................6-36
H
Handlebar switches ..............................3-10
Dimmer switch ..................................3-10
Engine stop switch ............................3-11
Horn switch .......................................3-10
Pass switch .......................................3-10
Start switch .......................................3-11
Turn signal switch .............................3-10
Headlight bulb, replacing ......................6-37I
Identification numbers ............................9-1
Ignition circuit cut-off system ................3-22
Indicator and warning lights ....................3-2
ABS warning light ................................3-2
High beam indicator light .....................3-3
Oil change indicator light .....................3-3
Turn signal indicator lights ...................3-2
K
Key identification number .......................9-1
L
License plate light bulb, replacing ........6-41
M
Main switch/steering lock .......................3-1
Model label .............................................9-2
P
Parking ...................................................5-5
Part locations ..........................................2-1
Periodic maintenance and lubrication
chart .....................................................6-3
Pre-operation check list ..........................4-1
R
Rider seat .............................................3-18
Rider seat, adjusting .............................3-18A
ABS ......................................................3-13
Acceleration and deceleration ................5-3
Air filter and V-belt case air filter
elements, cleaning ............................6-21
Air flow louver .......................................6-23
Anti-theft alarm (optional) .....................3-10
B
Battery ..................................................6-34
Battery cover removal ..........................6-34
Brake fluid level, checking ....................6-29
Brake fluid, changing ............................6-30
Brake lever, front ..................................3-11
Brake lever, rear ...................................3-12
Brake levers, lubricating .......................6-31
Braking ...................................................5-3
C
Cables, checking and lubricating ..........6-30
Care ........................................................7-1
Catalytic converter ................................3-17
Centerstand and sidestand, checking
and lubricating ..................................6-31
Conversion table ....................................8-5
Coolant .................................................6-19
Coolant temperature gauge ....................3-5
Cowlings and panel, removing and
installing ..............................................6-6
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S
Safe-riding points ...................................1-2
Shock absorber assemblies,
adjusting ............................................3-21
Sidestand .............................................3-22
Spark plug, checking ............................6-12
Specifications .........................................8-1
Speedometer ..........................................3-4
Starting off ..............................................5-2
Starting the engine .................................5-1
Steering, checking ................................6-33
Storage ...................................................7-4
Storage compartments .........................3-19
T
Tachometer ............................................3-4
Tail/brake light bulb, replacing ..............6-40
Throttle cable free play, adjusting ........6-23
Throttle grip and cable, checking and
lubricating ..........................................6-31
Tires .....................................................6-24
Tool kit ....................................................6-1
Troubleshooting ....................................6-42
Troubleshooting charts .........................6-43
Turn signal light bulb (front),
replacing ............................................6-39
Turn signal light bulb (rear),
replacing ............................................6-40
V
Valve clearance, adjusting ...................6-23
Vehicle identification number .................9-1W
Wheel bearings, checking ....................6-33
Wheels .................................................6-26
INDEX
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