maintenance YAMAHA MAJESTY 250 2003 Owner's Manual

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
button, otherwise repeat the proce-
dure.
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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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.
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8 8
Make sure that no foreign
material enters the final trans-
mission case.
8 8
Make sure that no oil gets on
the tire or wheel.
1
1. Final transmission oil drain bolt
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 transmission oil filler cap
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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PERIODIC MAINTENANCE AND MINOR REPAIR
67. Check the final transmission
case for oil leakage. If oil is leak-
ing, check for the cause.
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
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.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. If the coolant is at or below the
minimum level mark, remove the
reservoir cap, add coolant to the
maximum level mark, and then
install the reservoir cap.
4. Install the battery cover.
1
1. Coolant reservoir cap
NOTE:
The radiator fan is automatically
switched on or off according to the
coolant temperature in the radiator. If
the engine overheats, see page 6-44
for further instructions.EC000080
cC
8
8
If 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.
8 8
If 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.
8 8
If 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.
Coolant reservoir capacity:
0.4 L
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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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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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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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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.
Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg175 kPa
(1.75 kgf/cm2,
1.75 bar)200 kPa(2.00 kgf/cm2,
2.00 bar)
90 kg load–maximum200 kPa(2.00 kgf/cm2,
2.00 bar)225 kPa(2.25 kgf/cm2,
2.25 bar)
EW000082
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8 8
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the tempera-
ture of the tires equals the
ambient temperature).
8 8
The 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* 178 kg
* Total weight of rider, passenger, cargo and
accessories
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EW000077
w
Because 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.
8 8
NEVER 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.
8 8
Do not carry along loosely
packed items, which can shift
during a ride.
8 8
Securely 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 depth
8 8
Adjust the suspension and tire
air pressure with regard to the
load.
8 8
Check the tire condition and
air pressure before each ride.
Minimum tire tread depth
(front and rear)1.6 mm
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
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.
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.
EAU00683
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8 8
Have 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.
8 8
The 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.
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
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