2003 YAMAHA MAJESTY 250 ABS

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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6-8
PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. Pull the cowling down slightly,
and then pull it outward as
shown.
EAU03632
Cowling BCowling *To remove the cowling
1. Pull up the right floorboard mats
as shown.
1
2
1. Mat A
2. Mat B
To install the cowling
1. Insert the tabs on the cowling
into the slots as shown, and then
install the screws.
2. Place the floorboard mats in the
original position.
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Take care not to damage the tabs
on the cowling when removing and
or installing it.
1
1. Tab (×10)
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6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
62. Remove the screws.
2 1
1
1. Screw (×4)
2. Cowling B
To install the cowling
1. Insert the tabs on the cowling
into the slots as shown, and then
install the screws.
2. Place the floorboard mats in the
original position.
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Take care not to damage the tabs
on the cowling when removing and
or installing it.
1
1. Tab (×10)
3. Pull the cowling down slightly,
and then pull it outward as
shown.
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6-10
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03617
Cowling C
To remove the cowling
1. Remove the cowling screws.
1
1. Screw (×2)
2. Push the cowling in lightly, and
then pull it back as shown.
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Take care not to damage the tabs
on the cowling when removing and
or installing it.
aa
a. Push.
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6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
6To install the cowling
1. Insert the tabs on the cowling
into the slots as shown, and then
push the cowling in until it snaps
into place.
2. Install the cowling screws.
1
2
1. Tab (×4)
2. Slot (×4)
EAU03628
Panel APanel *To remove the panel
Remove the bolts, and then pull the
panel out as shown.
1
2
1. Bolt (×2)
2. Panel A
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6-30
PERIODIC MAINTENANCE AND MINOR REPAIR
6 8Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking perfor-
mance.
8Be careful that water or dust
does not enter the brake fluid
reservoir when refilling. Water
will significantly lower the boiling
point of the fluid and may result
in vapor lock, and dirt may clog
the ABS hydraulic unit valves.
8Brake fluid may deteriorate paint-
ed surfaces or plastic parts.
Always clean up spilled fluid
immediately.
8As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if
the brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
EAU02962
Checking and lubricating the
cables
Cables, checking and lubricatingThe operation of all control cables
and the condition of the cables
should be checked before each ride,
and the cables and cable ends
should be lubricated if necessary. If
a cable is damaged or does not move
smoothly, have a Yamaha dealer
check or replace it.
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w
Damage to the outer sheath may
interfere with proper cable opera-
tion and will cause the inner cable
to rust. Replace a damaged cable
as soon as possible to prevent
unsafe conditions.
EAU03976
Changing the brake fluidBrake fluid, changingHave a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addi-
tion, have the oil seals of the master
cylinders and calipers as well as the
brake hoses replaced at the intervals
listed below or whenever they are
damaged or leaking.
8Oil seals: Replace every two
years.
8Brake hoses: Replace every four
years.Recommended lubricant:
Engine oil
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6-36
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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8
8
Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.
8 8
To charge a sealed-type (MF)
battery, a special (constant-
voltage) battery charger is
required. Using a conventional
battery charger will damage
the battery. If you do not have
access to a sealed-type (MF)
battery charger, have a
Yamaha dealer charge your
battery.
1. Turn the key to “OFF” and turn
off all electrical circuits.
2. Remove the blown fuse, and
then install a new fuse of the
specified amperage.
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Do not use a fuse of a higher
amperage rating than recommend-
ed to avoid causing extensive
damage to the electrical system
and possibly a fire.
EAU04110*
Replacing the fusesFuses, replacingThe fuse boxes are located under the
battery cover. (See page 6-34 for bat-
tery cover removal and installation
procedures.)
If a fuse is blown, replace it as fol-
lows.
4
5
79
6
18
3
2
910
1. Main fuse
2. Backup fuse (clock)
3. ABS control unit fuse
4. Radiator fan fuse
5. Ignition fuse
6. Headlight fuse
7. Signaling system fuse
8. ABS motor fuse
9. Spare fuse (×5)
10. Spare main fuse
Specified fuses:
Main fuse: 30 A
Backup fuse (clock): 10 A
ABS control unit fuse: 10 A
Radiator fan fuse: 4 A
Ignition fuse: 7.5 A
Headlight fuse: 15 A
Signaling system fuse: 15 A
ABS motor fuse: 30 A
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7-3
SCOOTER CARE AND STORAGE
7After cleaning
1. Dry the scooter with a chamois
or an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally
induced discoloring of stainless-
steel exhaust systems can be
removed through polishing.)
3. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal, includ-
ing chrome- and nickel-plated,
surfaces.
4. Use spray oil as a universal
cleaner to remove any remaining
dirt.
5. Touch up minor paint damage
caused by stones, etc.6. Wax all painted surfaces.
7. Let the scooter dry completely
before storing or covering it.
EWA00002
w
8 8
Make sure that there is no oil
or wax on the brakes or tires.
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild
detergent.
8 8
Before operating the scooter
test its braking performance
and cornering behavior.
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8
8
Apply spray oil and wax spar-
ingly and make sure to wipe
off any excess.
8 8
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
8 8
Avoid using abrasive polish-
ing compounds as they will
wear away the paint.
NOTE:
Consult a Yamaha dealer for advice
on what products to use.
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