check engine light YAMAHA MAJESTY 250 2003 Owners Manual

2-2
DESCRIPTION
2
9. Passenger seat
10. Rider seat (page 3-18)
11. Air flow louver (page 6-23)
12. Headlight (page 6-37)
13. Radiator 14. Battery (page 6-34)
15. Fuse box (page 6-36)
16. Coolant reservoir cap (page 6-20)
17. Coolant level check window (page 6-19)
18. Engine oil filler cap (page 6-15)11
12
13 16 17
18
14 15
109Right view
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3-2
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU03733
.(Parking)
The steering is locked, and the tail-
light, license light and auxiliary light
are on, but all other electrical sys-
tems are off. The key can be
removed.
To turn the main switch to “
.”:
1. Turn the key to “LOCK”.
2. Slightly turn the key counter-
clockwise until it stops.
3. While still turning the key coun-
terclockwise, push it in until it
snaps into place.
ECA00043
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Do not use the parking position for
an extended length of time, other-
wise the battery may discharge.
EAU04901
ABS warning light “”ABS warning lightECA00019
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If the ABS warning light comes on
or flashes while riding, the ABS
may be defective. If this occurs,
have a Yamaha dealer check the
electrical circuit.
See page 3-13 for an explanation of
the ABS.
The electrical circuit of the warning
light can be checked by setting the
engine stop switch to “#” and turning
the key to “ON”.
The warning light should come on for
a few seconds, and then go off. If the
warning light does not come on or
remains on, have a Yamaha dealer
check the electrical circuit.
EAU03034
Indicator and warning lightsIndicator and warning lightsEAU04121
Turn signal indicator lights “4”
and “6”
Turn signal indicator lightsThe corresponding indicator light
flashes when the turn signal switch is
pushed to the left or right.
13
45
2
1. Left turn signal indicator light “4”
2. ABS warning light “”
3. High beam indicator light “&”
4. Oil change indicator light “
7”
5. Right turn signal indicator light “6”
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3-3
EWA00069
w
When the ABS warning light
comes on or flashes while riding,
the brake system reverts to con-
ventional braking. Therefore, be
careful not to cause the wheel to
lock during emergency braking.
NOTE:
The ABS warning light may come on
while pushing the start switch and
while accelerating the engine with the
scooter on its centerstand, but this
does not indicate a malfunction.
EAU00063
High beam indicator light “&”High beam indicator lightThis indicator light comes on when
the high beam of the headlight is
switched on.
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU03734
Oil change indicator light “7”Oil change indicator lightThis indicator light comes on at the
initial 1,000 km and every 3,000 km
thereafter to indicate that the engine
oil should be changed.
If the engine oil is changed before the
oil change indicator comes on (i.e.
before the periodic oil change interval
has been reached), the indicator light
must be reset after the oil change for
the next periodic oil change to be
indicated at the correct time. (See
page 6-17 for the resetting proce-
dure.)
The electrical circuit of the indicator
light can be checked according to the
following procedure.
1. Set the engine stop switch to “#”
and turn the key to “ON”.
2. Check that the indicator comes
on for a few seconds and then
goes off.
3. If the indicator light does not
come on, have a Yamaha dealer
check the electrical circuit.
NOTE:
The oil change indicator light may
flash when the engine is revved with
the scooter on the centerstand, but
this does not indicate a malfunction.
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3-22
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU00330
SidestandSidestandThe sidestand is located on the left
side of the frame. Raise the side-
stand or lower it with your foot while
holding the scooter upright.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain situ-
ations. (See further down for an
explanation of the ignition circuit cut-
off system.)
1
1. Sidestand switch
EAU00337
Ignition circuit cut-off
system
Ignition circuit cut-off systemThe ignition circuit cut-off system
(comprising the sidestand switch and
brake light switches) has the follow-
ing functions.
8It prevents starting when the
sidestand is up, but neither brake
is applied.
8It prevents starting when either
brake is applied, but the side-
stand is still down.
8It cuts the running engine when
the sidestand is moved down.
Periodically check the operation of
the ignition circuit cut-off system
according to the following procedure.
EW000045
w
If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
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w
The scooter must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up),
otherwise the sidestand could con-
tact the ground and distract the
operator, resulting in a possible
loss of control. Yamaha’s ignition
circuit cut-off system has been
designed to assist the operator in
fulfilling the responsibility of rais-
ing the sidestand before starting
off. Therefore, check this system
regularly as described below and
have a Yamaha dealer repair it if it
does not function properly.
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3
2
1
1. Start switch
2. Front brake lever
3. Rear brake lever
5-1
EAU00372
OPERATION AND IMPORTANT RIDING POINTS
5
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w
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.
EAU03616*
Starting the engineStarting the engineEC000046
cC
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.
EW000054
w
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 “#”.
ECA00068
cC
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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5-4
OPERATION AND IMPORTANT RIDING POINTS
5
EAU04755
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).
EAU01128
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.
EAU04590
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.
ECA00138
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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.
ECA00137
cC
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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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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6-4
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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6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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.
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
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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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