transmission YAMAHA MAJESTY 250 2003 Owners Manual

4-1
EAU01114
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.
EAU03439
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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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
cC
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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6-5
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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6-18
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.
EWA00062
w
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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6-19
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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8-2
SPECIFICATIONS
8
Final transmission oil
Type Engine oil SAE 10W-30
(API SE)
Total amount 0.25 L
Radiator capacity
(including all routes)1.4 L
Air filterWet type element
Fuel
Type REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity 12 L
Carburetor
Manufacturer TEIKEI
Model × quantity Y28V-1E × 1
Spark plug
Manufacturer/model NGK/DR8EA
Spark plug gap 0.6–0.7 mm
Clutch typeDry, centrifugal automatic
Transmission
Primary reduction system Helical gear
Primary reduction ratio 40/15 (2.666)
Secondary reduction system Helical gear
Secondary reduction ratio 38/15 (2.533)Transmission type V-belt automatic
Operation Centrifugal automatic type
Chassis
Frame type Steel tube underbone
Caster angle 28°
Trail 103 mm
Tires
Front
Type Tubeless
Size 110/90-12 64L
Manufacturer/ IRC/MB67
model MICHELIN/BOPPER
Rear
Type Tubeless
Size 130/70-12 62L
Manufacturer/ IRC/MB67
model MICHELIN/BOPPER
Maximum load* 178 kg
Air pressure (cold tire)
up to 90 kg load*
Front175 kPa (1.75 kgf/cm
2, 1.75 bar)
Rear 200 kPa (2.00 kgf/cm
2, 2.00 bar)
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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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