2002 YAMAHA MAJESTY 250 Oil filter

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 ..........6-31
Checking and lubricating the centerstand
and sidestand ....................................................6-31Checking 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
5SJ-28199-E0 1/24/02 6:14 PM Page 49

6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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
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.
5SJ-28199-E0 1/24/02 6:14 PM Page 54

6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03627
Air filter and V-belt case air
filter elementsAir 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
cC8Make sure that each filter ele-
ment is properly seated in its
case.
8The engine should never be
operated without the filter ele-
ments installed, otherwise the
piston and/or cylinder may
become excessively worn.
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
3
4
1. Air filter case cover
2. Screw (×5)
3. Sponge material
4. Mesh sheet
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.
5SJ-28199-E0 1/24/02 6:14 PM Page 70

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. Recommended oil:
Engine oil
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.2
1
1. V-belt case air filter cover
2. Screw (×3)
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.
2
1
1. V-belt case air filter cover
2. V-belt case air filter element
5SJ-28199-E0 1/24/02 6:14 PM Page 71

8-2
SPECIFICATIONS
8
Final gear case 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* 185 kg
Air pressure (cold tire)
up to 90 kg load*
Front175 kPa (1.75 kgf/cm
2, 1.75 bar)
Rear200 kPa (2.00 kgf/cm2, 2.00 bar)
5SJ-28199-E0 1/24/02 6:14 PM Page 103

INDEX
F
Final transmission oil ............................6-18
Front and rear brake lever free play,
adjusting ............................................6-27
Front fork, checking ..............................6-32
Fuel ......................................................3-14
Fuel consumption, tips for reducing .......5-4
Fuel gauge .............................................3-4
Fuel tank cap ........................................3-13
Fuses, replacing ...................................6-36
H
Handlebar switches ..............................3-10
Dimmer switch ...................................3-10
Engine stop switch .............................3-12
Headlight variations ...........................3-11
Horn switch ........................................3-10
Pass switch ........................................3-10
Start switch ........................................3-12
Turn signal switch ..............................3-10
Headlight bulb, replacing ......................6-37
I
Identification numbers ............................9-1
Ignition circuit cut-off system ................3-21
Indicator lights ........................................3-2
High beam indicator light .....................3-2
Oil change indicator light .....................3-2
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 .............................................3-16
Rider seat, adjusting .............................3-17
S
Safe-riding points ...................................1-2
Shock absorber assemblies,
adjusting ............................................3-19
Sidestand .............................................3-20
Spark plug, checking ............................6-12
Specifications .........................................8-1
Speedometer ..........................................3-3
Starting off ..............................................5-2
Starting the engine .................................5-1
Steering, checking ................................6-33
Storage ...................................................7-4
Storage compartments .........................3-17
A
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) .......................3-9
B
Battery ..................................................6-34
Battery cover removal ..........................6-34
Brake fluid level, checking ....................6-29
Brake fluid, changing ............................6-30
Brake lever, front ..................................3-12
Brake lever, rear ...................................3-13
Brake levers, lubricating .......................6-31
Braking ...................................................5-3
C
Cables, checking and lubricating ..........6-30
Care ........................................................7-1
Catalytic converter ................................3-15
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
E
Engine break-in ......................................5-4
Engine oil ..............................................6-14
5SJ-28199-E0 1/24/02 6:14 PM Page 110