2002 YAMAHA MAJESTY 250 brake light

INSTRUMENT AND CONTROL FUNCTIONSMain switch/steering lock ...................................................................3-1
Indicator lights ...................................................................................3-2
Speedometer .....................................................................................3-3
Tachometer .......................................................................................3-3
Fuel gauge .........................................................................................3-4
Coolant temperature gauge ...............................................................3-5
Multi-function display .........................................................................3-5
Anti-theft alarm (optional) ..................................................................3-9
Handlebar switches .........................................................................3-10
Front brake lever .............................................................................3-12
Rear brake lever ..............................................................................3-13
Fuel tank cap ...................................................................................3-13
Fuel ..................................................................................................3-14
Catalytic converter ...........................................................................3-15
Rider seat ........................................................................................3-16
Adjusting the rider seat ....................................................................3-17
Storage compartments ....................................................................3-17
Adjusting the shock absorber assemblies .......................................3-19
Sidestand .........................................................................................3-20
Ignition circuit cut-off system ...........................................................3-21
3
5SJ-28199-E0 1/24/02 6:14 PM Page 15

3-21
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU00337
Ignition circuit cut-off
systemIgnition 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
wIf a malfunction is noted, have a
Yamaha dealer check the system
before riding.
5SJ-28199-E0 1/24/02 6:14 PM Page 36

4-2
PRE-OPERATION CHECKS
4
Rear brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-13, 6-27–6-30
Throttle grip•Make sure that operation is smooth.
•Check cable free play.
•If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-23, 6-31
Wheels and tires•Check for damage.
•Check tire condition and tread depth.
•Check air pressure.
•Correct if necessary.6-24–6-27
Brake levers•Make sure that operation is smooth.
•Lubricate lever pivoting points if necessary.3-12–3-13, 6-27, 6-31
Centerstand, sidestand•Make sure that operation is smooth.
•Lubricate pivots if necessary.6-31–6-32
Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.
•Tighten if necessary.—
Instruments, lights, signals
and switches•Check operation.
•Correct if necessary.3-2–3-12, 6-37–6-42
Sidestand switch•Check operation of ignition circuit cut-off system.
•If system is defective, have Yamaha dealer check vehicle.3-20–3-22 ITEM CHECKS PAGE
5SJ-28199-E0 1/24/02 6:14 PM Page 41

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

6-4
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 3-2 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
5SJ-28199-E0 1/24/02 6:14 PM Page 53

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

6-40
PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. Remove the socket (together
with the bulb) by turning it coun-
terclockwise.
4. Remove the defective bulb by
pulling it out.
5. Insert a new bulb into the socket.
6. Install the socket (together with
the bulb) by turning it clockwise.
7. Install the cowling.
1
1. Socket
EAU03618
Replacing a rear turn signal
light bulbTurn signal light bulb (rear), replacing1. Place the scooter on the center-
stand.
2. Remove cowling C. (See page
6-10 for cowling removal and
installation procedures.)
EAU03619
Replacing a tail/brake light
bulbTail/brake light bulb, replacing1. Place the scooter on the center-
stand.
2. Remove cowling C. (See page
6-10 for cowling removal and
installation procedures.)
5SJ-28199-E0 1/24/02 6:14 PM Page 89

7-2
SCOOTER CARE AND STORAGE
7 8Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abra-
sive cleaning products, sol-
vent or thinner, fuel (gasoline),
rust removers or inhibitors,
brake fluid, antifreeze or elec-
trolyte.
8Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the
following areas: seals (of
wheel and swingarm bearings,
fork and brakes), electric com-
ponents (couplers, connec-
tors, instruments, switches
and lights), breather hoses
and vents.8For scooters equipped with a
windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure that it
does not leave any marks. If
the windshield is scratched,
use a quality plastic polishing
compound after washing.
After normal useRemove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottle-
brush for hard-to-reach areas.
Stubborn dirt and insects will come
off more easily if the area is covered
with a wet cloth for a few minutes
before cleaning.After riding in the rain, near the sea
or on salt-sprayed roadsSince sea salt or salt sprayed on the
roads during winter are extremely
corrosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads.NOTE:
Salt sprayed on roads in the winter
may remain well into spring.1. Clean the scooter with cold water
and a mild detergent after the
engine has cooled down.
ECA00012
cCDo not use warm water since it
increases the corrosive action of
the salt.2. Apply a corrosion protection
spray on all metal, including
chrome- and nickel-plated, sur-
faces to prevent corrosion.
5SJ-28199-E0 1/24/02 6:14 PM Page 97